Abstract: A refractory mold is disclosed. The refractory mold includes a fugitive pattern assembly comprising a hollow sprue that comprises a sprue wall disposed about a longitudinal axis; a pattern disposed outwardly of the sprue wall; and an outwardly extending gate attached to and extending between the sprue wall and the pattern, the hollow sprue, pattern and gate each formed from a fugitive material; and a refractory mold formed on and having a mold cavity defined by an outer surface of the fugitive pattern assembly.

Abstract: A refractory mold is disclosed. The refractory mold includes a fugitive pattern assembly comprising a hollow sprue that comprises a sprue wall disposed about a longitudinal axis; a pattern disposed outwardly of the sprue wall; and an outwardly extending gate attached to and extending between the sprue wall and the pattern, the hollow sprue, pattern and gate each formed from a fugitive material; and a refractory mold formed on and having a mold cavity defined by an outer surface of the fugitive pattern assembly.

Abstract: A radial pattern assembly is disclosed. The assembly includes a hollow sprue comprising a sprue wall disposed about a longitudinal axis, the sprue wall having a thickness, a length and a periphery. The assembly also includes a pattern disposed radially outwardly of the sprue wall. The assembly further includes a radially outwardly extending gate attached to and extending between the sprue wall and the pattern, the hollow sprue, pattern and gate each formed from a fugitive material.

Abstract: A method of making a radial pattern assembly is disclosed. The method includes forming a hollow sprue comprising a sprue wall disposed about a longitudinal axis, the sprue wall having a thickness, a length and a periphery; a pattern disposed outwardly of the sprue wall; and an outwardly extending gate attached to and extending between an outer surface of the sprue wall and the pattern, the hollow sprue, pattern and gate each formed from a fugitive material.

Abstract: A refractory mold is disclosed. The refractory mold includes a fugitive pattern assembly comprising a hollow sprue that comprises a sprue wall disposed about a longitudinal axis; a pattern disposed outwardly of the sprue wall; and an outwardly extending gate attached to and extending between the sprue wall and the pattern, the hollow sprue, pattern and gate each formed from a fugitive material; and a refractory mold formed on and having a mold cavity defined by an outer surface of the fugitive pattern assembly.

Abstract: A method of making a radial pattern assembly is disclosed. The method includes forming a hollow sprue comprising a sprue wall disposed about a longitudinal axis, the sprue wall having a thickness, a length and a periphery; a pattern disposed outwardly of the sprue wall; and an outwardly extending gate attached to and extending between an outer surface of the sprue wall and the pattern, the hollow sprue, pattern and gate each formed from a fugitive material.

Abstract: A radial pattern assembly is disclosed. The assembly includes a hollow sprue comprising a sprue wall disposed about a longitudinal axis, the sprue wall having a thickness, a length and a periphery. The assembly also includes a pattern disposed radially outwardly of the sprue wall. The assembly further includes a radially outwardly extending gate attached to and extending between the sprue wall and the pattern, the hollow sprue, pattern and gate each formed from a fugitive material.

Abstract: Countergravity casting of metals and metal alloys provides for melting of the metallic material under subambient pressure, evacuation of a gas permeable or impermeable mold under subambient pressure, and controlled, rapid filling of the mold while it is maintained under the subambient pressure by applying gas pressure locally on the molten metallic material in a sealed space defined by engagement of a mold base and a melting vessel with a seal therebetween. The gas pressure applied locally in the sealed space establishes a differential pressure on the molten metallic material to force it upwardly through the fill tube into the mold.

Abstract: Method and apparatus for countergravity casting a plurality of articles wherein a ceramic mold is provided having an upstanding riser passage and a plurality of mold cavities disposed along a length of the riser passage at different elevations, each mold cavity communicating to the riser passage via a gate passage, wherein molten metal is forced to flow upwardly from a source into the riser passage for supply to the mold cavities via their gate passages, wherein the mold is rotated so that molten metal that resides in the gate passages is subjected to centrifugal force in a direction toward the mold cavities, and wherein molten metal in the riser passage is drained to empty the riser passage before molten metal in the mold cavities and the gate passages solidifies, leaving the gate passages at least partially filled with molten metal for supply to the mold cavities in response to shrinkage as molten metal therein solidifies while the container is rotated.

Abstract: A vaporizable refractory coated pattern assembly is formed having a sprue connected to a plurality of thin wall patterns of articles to be cast. The pattern assembly is supported in a refractory particulate media in an open bottom container that is evacuated to subambient pressure and rotated in a manner to distribute particulates to regions of the refractory coated patterns not yet directly contacted by particulates. The pattern assembly is comprised of relatively dense foam plastic pattern material that imparts increased strength to the thin wall patterns. The sprue includes a vent passage that communicates to a particulate media to vent pattern decomposition vapors thereto in a manner that enables faster replacement of the pattern assembly in the media, despite the use of the relatively dense pattern material.

Abstract: Method and apparatus for melting reactive metallic materials, such as for example titanium base alloys and other reactive alloys, by selective and sequential induction heating of a plurality of solid alloy charge components segregated in a refractory melting vessel in a manner to effect rapid top-to-bottom melting that avoids harmful reaction of the melt with refractory melting vessel material and contamination of the melt.

Abstract: Method and apparatus for directional solidification (e.g columnar grain or single crystal casting) of a melt involves refractory particulates, such as SiC particles, provided about at least one article molding cavity region of a casting mold wherein the particulates are heated to an elevated temperature above a melt casting temperature. The article molding cavity region of the casting mold is heated from an initial preheat temperature to an elevated casting temperature by heat from the particulates prior to communication of the article molding cavity to a chill member. For single crystal casting, a radiation transparent crystal selector member is disposed in a mold grain nucleation and growth cavity located between the article molding cavity and the chill member to select a single crystal for propagation in the article molding cavity region. A melt permeable, thermal insulation member may be disposed between the mold grain nucleation and growth cavity region and the chill member.

Abstract: A method for the countergravity casting of a melt involves placing a refractory mold in a vacuum chamber defined within a casting box where the mold may be optionally surrounded by support particulates in the vacuum chamber. The mold includes a mold cavity and a serpentine melt inlet passage formed by nested refractory members below the mold cavity and in melt flow communication therewith. The serpentine melt inlet passage is communicated with a fill tube extending from the casting chamber toward an underlying source of melt. The mold/chamber and the source are relatively moved to engage the fill tube and the source. A differential pressure is applied between the mold cavity and the source to urge the melt upwardly through the fill tube and serpentine melt inlet passage into the mold cavity. The mold/chamber and the source are then relatively moved to disengage the fill tube and the source after the mold cavity is filled with the melt.

Abstract: The present invention involves a method and apparatus for making an intermetallic casting (e.g. a titanium, nickel, iron, etc. aluminide casting) wherein a charge of a solid first metal protected from air as required is disposed in a vessel, and a charge of a second metal that reacts exothermically with the first metal is melted in another vessel. The molten second metal is introduced to the vessel containing the charge of the first metal so as to contact the first metal. The first and second metals are heated in the vessel to exothermically react them and form a melt for gravity or countergravity casting into a mold. The exothermic reaction between the first and second metals releases substantial heat that reduces the time needed to obtain a melt ready for casting into a mold. In particular, the exothermic reaction between the first and second metals, in effect, reduces the residence time of the intermetallic melt in the vessel.

Abstract: A wear-resistant cast iron rocker arm or similar machine element is formed by differential pressure, countergravity casting an iron melt of low superheat into a ceramic investment shell mold maintained initially at room temperature and rapidly solidifying the melt therein to provide a wear-resistant, as-cast microstructure throughout the body of the element. The as-cast microstructure comprises a dendritic constituent of austenite or transformed austenite (e.g., pearlite) depending on alloy composition and an interdendritic carbide constituent. Interdendritic ledeburite will also be present if the austenite remains untransformed. The as-cast microstructure of the rocker arm is devoid of graphite.

Abstract: Method and apparatus for the differential pressure, countergravity casting of molten metal in shortened cycle times into a casting mold having an inlet passage-forming collar that provides a dam to reduce runout of the melt from the mold during tilting of the mold from the casting position to an inverted solidification position.

Abstract: A wear-resistant cast iron rocker arm or similar machine element is formed by differential pressure, countergravity casting an iron melt of low superheat into a ceramic investment shell mold maintained initially at room temperature and rapidly solidifying the melt therein to provide a wear-resistant, as-cast microstructure throughout the body of the element. The as-cast microstructure comprises a dendritic constituent of austenite or transformed austenite (e.g., pearlite) depending on alloy composition and an interdentritic carbide constituent. Interdendritic ledeburite will also be present if the austenite remains untransformed. The as-cast microstructure of the rocker arm is devoid of graphite.

Abstract: A method and apparatus for countergravity casting of molten metal with exclusion of air in a gas-pervious mold sealed in an evacuable chamber having a free end of a fill pipe for the mold cavities projecting therefrom. The fill pipe is moved relative to an enclosed crucible containing the molten metal under an air-free atmosphere of inert gas to project the fill pipe free end into the crucible enclosure to a position below the molten metal so that evacuation of the chamber produces filling of the mold. Entry of air into the crucible enclosure is prevented by maintaining the surface of the molten metal and the ambient atmosphere a sufficient distance apart prior to insertion of the fill pipe to prevent circulating air currents from drawing air down to the metal or by blocking entry into the crucible enclosure. Entry of air can be further prevented by maintaining a sufficient pressure of inert gas in the crucible enclosure and by sealing the upper portion of the fill pipe between the chamber and the mold.

Abstract: A refractory mold is disclosed. The refractory mold includes a fugitive pattern assembly comprising a hollow sprue that comprises a sprue wall disposed about a longitudinal axis; a pattern disposed outwardly of the sprue wall; and an outwardly extending gate attached to and extending between the sprue wall and the pattern, the hollow sprue, pattern and gate each formed from a fugitive material; and a refractory mold formed on and having a mold cavity defined by an outer surface of the fugitive pattern assembly.

Abstract: A radial pattern assembly is disclosed. The assembly includes a hollow sprue comprising a sprue wall disposed about a longitudinal axis, the sprue wall having a thickness, a length and a periphery. The assembly also includes a pattern disposed radially outwardly of the sprue wall. The assembly further includes a radially outwardly extending gate attached to and extending between the sprue wall and the pattern, the hollow sprue, pattern and gate each formed from a fugitive material.