Abstract: A molten metal mold casting system with a cooling system which maintains an approximately equal coolant flow rate while altering flow characteristic of the coolant flow discharged toward the castpart to alter the cooling affects on the emerging castpart. The heat transfer at the center surface portion of the castpart is reduced for some low thermal conductivity alloy metals, which reduces the butt curl during casting.

Abstract: A lubrication control system for use with or in a metal casting mold. Aspects of the invention include a lubricant flow stop or plug which prevents or controls the flow of lubricant from the mold during non-casting times.

Abstract: When the starter block commences reciprocating along the axis of an open ended mold cavity, with a body of start up material in tandem with it, successive layers of molten metal are relatively superimposed on the body of start up material, and layers thereof are confined to a first cross sectional area of the cavity but permitted to distend relatively peripherally outwardly from the circumferential outline of the first cross sectional area at relatively peripherally outwardly inclined angles to the axis while thermal contraction forces are generated in the respective layers and the magnitude of the forces is controlled so that the thermal contraction forces counterbalance the splaying forces in the respective layers and confer a free-formed circumferential outline on the resulting body of metal as it becomes form-sustaining.

Abstract: When the starter block commences reciprocating along the axis of an open ended mold cavity, with a body of start up material in tandem with it, successive layers of molten metal are relatively superimposed on the body of start up material, and layers thereof are confined to a first cross sectional area of the cavity but permitted to distend relatively peripherally outwardly from the circumferential outline of the first cross sectional area at relatively peripherally outwardly inclined angles to the axis while thermal contraction forces are generated in the respective layers and the magnitude of the forces is controlled so that the thermal contraction forces counterbalance the splaying forces in the respective layers and confer a free-formed circumferential outline on the resulting body of metal as it becomes form-sustaining.

Abstract: An opening 206 is provided in a system for delivering molten metal to the mold cavity 18 of a molten metal casting apparatus. A valve closure device 192, 196 is mounted at 198 to be reciprocated in relation to the opening 206 to control the flow of molten metal therethrough, and the driven end 206 of a bellows motor 208 is connected with the valve closure device at 258 to reciprocate the device in relation to the opening. A pair of concentric relatively inside and outside thimble-shaped chambers 238 and 240, 264 is circumposed about the bellows motor so that the bight portions thereof are opposed to the driven end of the motor, and interconnected with one another by a restricted liquid flow passage 270 in the screw 268. When fluid input signals are generated in the relatively outside chamber 240, 264, for the actuation of the closure device through the bellows motor, each signal is transmitted to the end of the bellows motor through the restricted liquid flow passage 270 and the relatively inside chamber 238.

Abstract: Balance beams are pivotally mounted on and crosswise of an elongated rack extending parallel to a trough over a series of mold cavities, valve closure devices are suspended from corresponding first end portions of the beams to throttle valve openings in the trough, float sensors are suspended from points on the opposing second end portions of the beams to contact the surfaces of molten metal columns brought to a state of equilibrium in the cavities, and the rack is elevated in relation to the cavities as molten metal is delivered to the trough, so that as the first end portions impose a desired value on the rate at which the surfaces escalate up the axes of the cavities, the second end portions elevate the suspension points for the sensors at a rate commensurate therewith, to assure that the input signals transmitted to the first portions through the fulcra for the beams, are consistent with the imposed value.

Abstract: To control the admission of molten metal to a series of mold cavities through a series of valve openings in the downspouts of a trough thereabove, an elongated rack is arranged parallel to the trough, a set of balance beams is pivotally mounted on the rack, a set of valve closure devices is suspended from corresponding first end portions of the beams for throttling the openings, and a set of float sensors is suspended from points on the opposing second end portions of the beams for contact with the surfaces of the molten metal in the cavities.

Abstract: The mold has a first chamber defined by a pair of inner and outer peripheral walls circumposed about the axis of the cavity and spaced apart from one another transverse the axis. The first chamber has oppositely disposed end walls that extend transverse the axis and an inlet for the supply of liquid coolant under pressure. The inner peripheral wall has a step which projects into the first chamber. The step has a first surface that extends transverse the axis and a second surface that extends parallel to the axis and coterminates with the first surface to form a corner. A second chamber is formed in the inner peripheral wall at the step. A series of holes open into the first chamber at one of the surfaces of the step to permit coolant to discharge into the second chamber at a reduced pressure. A passage opening discharges the reduced pressure coolant onto a body of metal emerging from the discharge end opening of the cavity.

Abstract: Disclosed is a system for providing a modular mold table for use in conjunction with a vertical non-ferrous metal casting apparatus. A plurality of longitudinal headers with a coolant passageway and transverse headers with a coolant passageway provide the mold table. A centralized water screen is provided to screen undesired inclusions in the coolant. Pre-cast modules which contain the mold cavities and other interconnections for coolant, oil and gas are operatively connected to the longitudinal headers and can be added or removed in building block fashion. Also disclosed is an oil delivery system and a gas delivery system wherein longitudinally oriented oil and gas passageways are included within the longitudinal headers.

Abstract: Disclosed is an apparatus for the prevention of unacceptable rotation control of a vertical non-ferrous metal casting apparatus during the casting process, and more particularly for aluminum. A guide key internal to the ram interacts with an inset keyway in the guide column to prevent the unacceptable rotation of the ram during casting.

Abstract: In direct cooling an ingot emerging from a mold, two sets 136 and 142 of liquid coolant streams are discharged onto the ingot from an annulus 62 circumposed about the lower end opening 72 of the mold. One set of streams, 136, is discharged downwardly at 22.5 degrees to the axis 12 of the mold, and the other, 142, is discharged downwardly at 45 degrees to the axis of the mold. The two sets are staggered to one another circumferentially of the mold, and because of the high angle of incidence of the 45 degree set to the axis of the mold, substantial portions of the 45 degree streams rebound from the surface of the ingot at their points 144 of impact with the ingot, and mushroom into corolla-like masses of air borne liquid coolant spray 146 lying crosswise the paths of the 22.5 degree streams, which in turn entrain the spray and impact the successive layers 138 of coolant therebelow with the spray.

Abstract: The apparatus includes a first chamber disposed about the mold cavity and defined by a top, a bottom, and walls extending between the top and bottom at the inner and outer peripheries of the first chamber. A liquid coolant is supplied under pressure to the first chamber through an inlet. A step is formed adjacent one of the corners between the top and bottom .and the inner peripheral wall of the first chamber, a circumferential groove is formed in the outer peripheral wall of the step, and an elastomeric sealing ring is sealingly engaged with the mouth of the groove to define a second chamber in the groove. Meanwhile, the shoulder of the step is spaced apart from the other corner of the first chamber, and a series of holes is formed in the shoulder to permit the coolant to pass into the second chamber at a reduced pressure. A passage then discharges the reduced pressure coolant onto a body of metal emerging from the discharge end opening of the cavity.

Abstract: A metal casting control device is provided for use in conjunction with a semi-continuous metal casting system. The control device is an integral module containing a metal surface elevation sensing device, a valve actuator for positioning a metal distribution control valve, and electronic circuits associated with these mechanical components. The control device module is adapted to be connected to an overhead metal distribution launder by a single quick-coupling for convenient and simple removal and replacement. Calibration of the control device is performed after installation by mounting a calibration target on the metal casting system and vertically adjusting the metal surface elevation sensing device until an integral calibration indicator positioned on the control device indicates that the proper vertical position has been attained.

Abstract: As a reversal of previous practice, the annular body of the mold in the unit has an annular case at the bottom thereof, rather than at the top thereof. The case is relatively thick axially of the mold, so as to form the greater portion of the axial length of the mold body at the outer periphery thereof; and at the top thereof, the case has an annular plate thereon, which forms a pair of flanges that overhang the case and enable the metal casting unit to be lowered into an aperture of a casting table from above, and supported on top of the table at the flanges. Meanwhile, the case defines the lower end opening of the mold cavity, and the outlet for liquid coolant that is discharged onto the molten metal body as it emerges from the unit. Commonly, the case is monolithic, and also has an annular sump at the top thereof which is covered by the plate to form a chamber for the coolant in the sump.

Abstract: A casting unit 6 consists of a monolithic body which is annular in shape and has an annular flange 72 outturned about the axis and monolithically outstanding on the body at the outer periphery, a set of lugs 110 angularly spaced about the axis on the lower end portion of the body and monolithically outstanding in the aperture, and a circumferential groove 114 about the outer periphery of the body in the upper end portion, with mullions 20 monolithically upstanding therein, adjacent the outer periphery of the groove, to form ports 112.The groove is interconnected with the cavity 108 in the lower end portion of the body at the aperture; and passages, 126, 140, a graphite ring 16, and whatever else is required, are added to complete the unit 6 before it is supported in an aperture in a metal casting table 2, having liquid coolant discharge means 14 circumposed thereabout and a stool to support molten metal after being mated with the lugs.

Abstract: A low-flexure molten metal distribution launder comprises an elongated structural beam which extends over a plurality of casting stations. A plurality of metal level sensors extend downward from the elongated structural beam to measure molten metal levels in underlying metal casting stations. A plurality of spaced U-shaped refractory hangers are supported within the structural beam to form a refractory channel. Refractory liners are received within the refractory hangers to form a molten metal trough within the structural beam. The hangers are spaced from each other and supported from the structural beam in such a way as to allow them to expand and contract relative to the structural beam without subjecting the structural beam to expansion and contraction. The walls of the refractory hangers are air-cooled to reduce heat transfer from the refractory hangers to the structural beam.