Abstract: A method for producing a casting core including: producing a casting core insert having a side surface section that is equal to a corresponding section of a side surface of the casting core from a casting core molding material; positioning the casting core insert in a mold cavity of a core box with the side surface section of the casting core insert in the place of the corresponding section of the side surface of the finished casting core, wherein a parting plane intersects the side surface section; introducing a casting core molding material into the mold cavity of the core box to form the remainder of the casting core, wherein the introduced casting core molding material comes into contact with the casting core insert; and solidifying the casting core molding material, thereby forming a shape-fit and/or material-fit connection between the introduced casting core molding material and the casting core insert.

Abstract: The invention makes available a tool for friction stir welding, which makes it possible, with reduced effort, to connect two panel elements that butt up against one another with one another by means of friction stir welding, in the case of which a tunnel is formed in the region of the abutting side surfaces, by means of recesses formed in the manner of a channel in the side surfaces in question.

Abstract: A method for recovery of moulding sand from a foundry sand mixture, which includes at least one proportion of moulding material fragments or loose moulding material grains, which accumulates when a cast part is demoulded from a casting mould as a result of the destruction of casting cores which have been formed from the moulding sand and an inorganic binder. The method includes: a) mixing the foundry sand mixture with cleaning water to form a slurry in order to dissolve the inorganic binder residues contained in the foundry sand mixture and optionally present additives from the moulding sand and to rinse them from the foundry sand mixture, and b) separating the cleaning water contaminated with the inorganic binder residues from the moulding sand contained in the slurry, wherein the process temperature of the slurry formed in step a) is 50 to 200° C.

Abstract: The invention provides a method for easily producing an engine block for a combustion engine. The method includes: a) providing an engine block with an open water jacket opening; b) placing an insert in the water jacket opening; and c) fixing the insert in the water jacket opening by friction welding. The shape of the insert is adapted to the shape of the water jacket opening such that the insert, when being placed, at least partially closes the water jacket opening and bridges the distance between the outer wall and the cylinder wall, thereby supporting the cylinder wall against the outer wall of the engine block. An engine block produced accordingly shows the advantages of a closed deck engine block.

Abstract: With the method according to the invention, mould parts for casting moulds for light metal casting can be treated such that the danger of crack formation in the region of the surface sections of the mould part coming into contact with the light metal melt during casting is reduced to a minimum.

Abstract: The invention relates to a method and a device for quantitive determination of a number and size of particulate components contained in a medium flowing along a flow channel. Ultrasonic waves are coupled into the flowing medium, which are reflected at least partially by the particulate components and reflected ultrasonic wave portions which are detected in a ultrasonic time signals, on which the quantitive determination is based. Amplitude values associated with the individual ultrasonic time signals, are detected which are each greater than an amplitude threshold value established for each ultrasonic time signal: The detected amplitude values are assigned to values describing the size and the number of the particulate components.

Abstract: A mold assembly cell for sand mold production comprising a turntable wherein sand cores and other mold parts (which together cooperate to define the casting cavity of the sand mold) are automatically and progressively assembled following a sequential pre-programmed schedule by programmable robots located in proximal relationship with the turntable and a core shooting machine. The assembly turntable rotates clockwise or counterclockwise to permit placement of progressively more-complete mold packages in each of at least three assembly stations to allow the robots to reach the molds being assembled at different angles for simultaneously setting the sand cores and other parts of the mold according to said pre-programmed assembly schedule. Also a mold assembly line comprising a plurality of the foregoing assembly cells to form sand molds for casting complex-geometry aluminum parts, such as aluminum engine blocks and cylinder heads, with greater flexibility, efficiency and productivity.

Abstract: A casting mould for casting complex-shaped castings from a molten metal. The casting mould has a mould cavity forming the casting and a delivery system that delivers molten metal into the mould cavity. The delivery system includes a sprue, a runner connected to the sprue and a feeder system connected to the runner. The mould cavity is connected to the feeder system or the runner via connections. When seen in the flow direction of the molten metal flowing from the sprue into the runner during the casting operation, the runner has a branch directed away from the sprue along the feeder system and has a directed-back branch adjoining the directed-away branch and guided along the feeder system in the opposite direction to the directed-away branch. The feeder system is connected to both the directed-away branch and the directed-back branch via two or more gates distributed along the respective branch.

Abstract: A foundry core formed from a moulding sand, grains of which are bound together by a binder, and which is provided to form a cooling channel in an engine block for an internal combustion engine. The foundry core has a supporting section, two neck sections, which protrude from a lateral surface of the supporting section and are arranged at a distance from one another, and at least one bridge section which is held by the neck sections at a distance from the supporting section and a minimum thickness of which measured as the distance between its lateral surfaces is no more than 3 mm in an area which lies between the neck sections.

Abstract: The present invention relates to a foundry core, which has the base form of a hollow body, with the foundry core being formed from a moulding material consisting of a mixture which is formed from a moulding sand and a binder and optionally from additives added to set its properties and a method for its manufacture. The foundry core according to the invention can be easily manufactured. This is achieved as a result of the foundry core being divided into at least two sub-segments and forming elements interacting with one another in a positive-locking manner being provided on the edge sides, with which sub-segments arranged adjacent to one another abut on one another, or in proximity to these edge sides, via which forming elements the sub-segments arranged adjacent to one another are fixed by positive locking immovably against one another at least in one direction.

Abstract: A mold assembly cell for sand mold production comprising a turntable wherein sand cores and other mold parts (which together cooperate to define the casting cavity of the sand mold) are automatically and progressively assembled following a sequential pre-programmed schedule by programmable robots located in proximal relationship with the turntable and a core shooting machine. The assembly turntable rotates clockwise or counterclockwise to permit placement of progressively more-complete mold packages in each of at least three assembly stations to allow the robots to reach the molds being assembled at different angles for simultaneously setting the sand cores and other parts of the mold according to said pre-programmed assembly schedule. Also a mold assembly line comprising a plurality of the foregoing assembly cells to form sand molds for casting complex-geometry aluminum parts, such as aluminum engine blocks and cylinder heads, with greater flexibility, efficiency and productivity.

Abstract: The present invention relates to a device for shooting a foundry core which surrounds a free inner space on its outer boundaries, with the device having a mould cavity representing the foundry core, which circulates around an inner slider extending along a longitudinal axis and is delimited on its outer side by an outer slider circulating around the mould cavity, with the clear width of the mould cavity being determined by the distance of the inner surface of the outer slider, assigned to the mould cavity, to the outer surface of the inner slider. The device according to the invention allows for operationally-safe manufacture of foundry cores that are tubular in their base form, but finely-structured in their walls and also on a large scale.

Abstract: Foundry cores, which consist of a mould material mixed from a binder and a mould sand, as well as optionally added additives, that are moulded in a complex way or are optimised with regard to their quality and which are provided for casting cast parts, can be produced by: a) moulding the foundry core by introducing the mould material into a foundry core mould; b) hardening the mould material; c) removing the foundry core from the foundry core mould; d) heating the foundry core to a deformation temperature; e) deforming the heated foundry core by applying a deformation force to the foundry core; and f) cooling the foundry core.

Abstract: The invention relates to a core box for manufacturing casting cores from a moulding material rigidified by supply of heat, including at least two core box parts, which together provide the shape of the casting cores to be manufactured and a heating device for heating the core box parts. The heating device has at least one oil line in thermal contact with at least one of the core box parts and connected to an oil supply feeding the oil line with a tempered oil for heating the core box parts. The invention divides at least one of the core box parts into a contour plate, providing the shape of the casting cores to be manufactured, and a heating plate connected to the contour plate, said heating plate extending flat over the contour plate and in which the oil line is provided.

Abstract: A casting apparatus including a casting die having at least two die halves movable relative to one another between a closed position and an open position, the die halves each comprising a front surface in which a recess is formed, an adjusting device for moving one of the die halves, and a clamping device switchable between a clamping position when the die is closed, and a release position when the die is open. The clamping device is an integral part of the die halves and includes a counter bearing and a locking device. In the clamping position, the locking device is in a form fitting engagement with the counter bearing to lock the die halves in the closed position, and in the release position, the locking device is released from the counter bearing to release the die halves from each other for opening of the die.

Abstract: A method for the practice-oriented, operationally reliable production of castings of an AlCu alloy which consists of Cu:, Mn:, Zr:, Fe:, Si:, Ti:, V:, remainder Al and unavoidable impurities. A melt which has been melted according to this alloy formula is kept at temperature for several hours and then mixed vigorously at least once. Thereafter, the melt is cast in portions into the respective casting which is then solution annealed at temperature for several hours. The casting is quenched from the solution anneal temperature to a maximum temperature of 300° C., at a specified cooling rate which the casting passes through during quenching. The casting is then artificially aged for several hours at 150-300° C. Finally, the casting is cooled to room temperature.

Abstract: A method for the production of castings which are permanently provided with readable information. An identification element, which has an information surface, provided with information, and a casting surface which is assigned to the casting and also provided with information, is arranged on a casting mould surface assigned to a mould cavity of a casting mould so that the information surface is covered, while the casting surface is exposed in the mould cavity. A metal melt is poured into the mould, so that, during casting or solidification of the metal melt, a firmly bonded, form-fit or force-fit connection of the identification element to the casting is produced. The information on the casting surface is reproduced in the manner of a stamp on surface of the casting. The casting is then removed from the mould and fettled.

Abstract: An enamel powder for manufacturing a coating is present as a mixture which contains 100 parts of a glass powder, 0.1-7.5 parts of ceramic fibers, glass fibers or carbon fibers, and alternatively to one another or in combination with one another 10-21 parts of a powdery oxidic compound of a light metal or 1-5 parts of a powder of a heavy metal. A metal component provided with the enamel powder withstands a flow of hot gas against it. The invention specifies a method, by means of which such metal components can be provided with an enamel coating.

Abstract: A method for demolding a casting from a casting mold having at least one casting core which images a passage opening in the casting connecting two outer sides of the casting and is produced from a molding material bound by a binder which decomposes under the influence of temperature, wherein the casting mold undergoes a heat treatment in a furnace for the demolding, during which it is heated to a temperature at which the binder loses its binding effect. In the furnace, hot gas is flowed through a passage formed in the casting core of the casting mold, the temperature of the hot gas corresponding at least to the temperature at which the binder of the molding material loses it binding effect such that the casting core decomposes into fragments or separate sand particles as a consequence of the influence of the hot gas.

Abstract: A casting mold is pivoted about a horizontal pivot axis for casting cast parts in a casting machine. The casting mold has a lid and a reference side wall. A main plane is placed into the reference side wall. A tundish is coupled to the casting mold and the casting mold is then pivoted into a pouring-in position. The tundish filled with a molten metal portion is pivoted with the casting mold about the pivot axis, so that the molten metal flows into the casting mold. An angle ?1 enclosed between the main plane of the reference side wall and a bath level of the molten metal portion in the tundish is constantly <180° until the melt hits the bottom of the casting mold.