Abstract: Various embodiments of making an investment casting mold are disclosed. The method includes coating a sacrificial pattern with a prime layer that includes a first refractory slurry and a first refractory stucco; at least partially hardening the prime layer; and coating the prime layer with an intermediate layer that includes a second refractory slurry and a second refractory stucco. The method further includes at least partially hardening the intermediate layer; coating the intermediate layer with a first backup layer that includes a first thixotropic agent, the first thixotropic agent including a first polymer emulsion; coating the first backup layer with a second backup layer that includes a second thixotropic agent, the second thixotropic agent including a second polymer emulsion; and at least partially hardening the first backup layer and the second backup layer.

Abstract: A green sand mold comprising at least one pair of green sand mold parts each comprising a recess and a mating surface, wherein a cured layer comprising a thermosetting resin as a main component is formed on the recess and mating surface of each green sand mold part, and wherein the cured layer has hardness of 40-98, a thickness of 0.5-6 mm, and gas permeability of 70-150, is produced by applying a curing material comprising the thermosetting resin as a main component and having viscosity of 1-100 mPa·S to the recess and mating surface of each green sand mold part, combining the green sand mold parts, and then heat-hardening the curing material.

Abstract: When pressing kneaded sand in a kneading sand tank into a mold by a pressing member, a pressing force applied to a kneaded sand layer in the kneading sand tank is monitored and a moving position of the pressing member is monitored from when the pressing member starts to move. A pressing start time at which the kneaded sand starts to flow into the mold is identified based on the pressing force applied to the kneaded sand layer in the kneading sand tank, and a pressing starting position of the pressing member at the pressing start time is identified. As a result, the pressing start time and the pressing starting position of the pressing member when the kneaded sand starts to flow into the mold are accurately identified, so the reliability of a filling evaluation of the kneaded sand into the mold is improved.

Abstract: A casting method includes preparing a thin shell mold which is sintered and placed in a box. Sands are buried in the box to encompass the thin shell mold. The pressure chamber is depressurized. The casting material is filled into the thin shell mold, such that the thin shell mold is disposed at a vacuum state. Then, the negative pressure of the pressure chamber is released. Then, the pressure chamber is pressurized, to form a pressure difference which presses the casting material to flow into the thin shell mold, thereby finishing the casting work. The temperature of the casting material is reduced, and the pressure in the pressure chamber is increased. Then, the casting material is cooled to form a casting product. Then, the thin shell mold is broken, and the casting product is removed.

Abstract: A clean cell environment for a continuous roll-over electric induction batch casting furnace system is provided where each combination of batch charge, for example an ingot, induction melting (ingot-melt) process and mold-pour process are performed in a clean cell environment and each combination ingot-melt and mold-pour process is traceable as to the identity of the specific ingot, or other charge form (composition) and the mold (fabrication identifier).

Abstract: A die casting machine with a die casting mold produces metal die cast parts. The die casting machine has a first machine shield, to which a first mold half of the die casting mold is secured, and a second machine shield, to which a second mold half of the die casting mold is secured. In order to compensate for the deflection of the machine shields, an intermediate plate which has at least two temperature-controlling devices that can be used to generate a temperature difference leading to the curving of the intermediate plate is arranged between the first machine shield and the first mold half and/or between the second machine shield and the second mold half.

Abstract: A transition plate for use in a direct chill (DC) casting system comprises a substantially annular body having an upper face and a lower face. At least a lower part of the body adjacent the lower face is made of a gas permeable refractory material, whereby gas can pass through the gas permeable refractory material and escape from the transition plate through at least the lower face.

Abstract: The moulding machine includes a moulding chamber having at least one chamber end wall (8) provided with a pattern plate adapted to form a pattern in a mould part and associated with a reference pattern block positioned in fixed relationship to a pattern of said pattern plate and adapted to form a reference pattern in an external face of a mould part. A detection system detects the position of a pattern face of the reference pattern of the sand mould part. A transverse and/or a rotational compaction position of a pattern plate is adjustable by means of at least one actuator (91, 92, 119). Said actuators are controlled by means of a control system on the basis of successive position detections performed by the detection system of pattern faces of reference patterns of compacted sand mould parts travelling along said path of travel.

Abstract: The subject matter of the invention is mold material mixtures for producing molds or cores for metal casting, consisting of at least one refractory base mold material, a binder and an additive based on factice. The invention also relates to a component system, a method for producing molds and cores using the mold material mixtures or the component system respectively, and to molds and cores produced by said method.

Abstract: Provided is vertical semi-continuous casting equipment including a guide device disposed under the mold to support the slab drawn from the plate, the guide device being configured to guide the descending of the slab. The guide device includes first and second guide parts including a plurality of guide rolls respectively disposed on both sides of a moving path of the plate under the mold to support the slab moving by the plate and guide the movement of the slab and a braking unit connected to each of the guide rolls to apply braking force to the guide roll that rotates by the movement of the slab. In accordance with an exemplary embodiment, the slab having the length longer than that of the slab in accordance with the related art may stably descend, the shaking of the slab may be prevented, and the casting speed may be stabilized.

Abstract: A process for producing a coupler knuckle and an improved coupler knuckle design are provided. The process produces a coupler knuckle by constructing a mold having the shape of the coupler knuckle. The mold is coated with a material that is resistant to melting at the molten melt temperatures of the molten metal used to form the knuckle. With the mold coated, the cavities in the mold interior are filled by placing an inert material therein. The molten metal used for forming the knuckle contacts the mold and consumes it, while the coating serves to provide a shape for the knuckle.

Abstract: A sand casting mold configured to cast a component and a method of forming the sand casting mold configured to cast the component by 3D printing are disclosed. The sand casting mold includes: an upper portion and a lower portion; a mold cavity defined by the upper portion and the lower portion; an upper sprue in the upper portion; a lower sprue which is in the lower portion and is in communication with the upper sprue; an upper runner which is in the upper portion, is separated from the upper sprue by a predetermined distance, and is in communication with the mold cavity; and a lower runner which is in the lower portion, is in communication with the lower sprue, is separated from the mold cavity in the lower portion, and has a first end in communication with the lower sprue, and a second end in communication with the upper runner. With the sand casting mold configured to cast the component according to the embodiments of the present invention, for example, a production cost can be reduced.

Abstract: A process for directional solidification of a cast part comprises energizing a primary inductive coil coupled to a chamber having a mold containing a material; energizing a primary inductive coil within the chamber to heat the mold via radiation from a susceptor, wherein the resultant electromagnetic field partially leaks through the susceptor coupled to the chamber between the primary inductive coil and the mold; determining a magnetic flux profile of the electromagnetic field; sensing a magnetic flux leakage past the susceptor within the chamber; generating a control field from a secondary compensation coil coupled to the chamber, wherein the control field controls the magnetic flux experienced by the cast part; and casting the material within the mold under the controlled degree of flux leakage.

Abstract: A flaskless molding machine includes: an upper flask; a lower flask; an upper sand tank; an upper plate attached to a lower end of the upper sand tank; a first lower sand tank; a second lower sand tank; a lower plate attached to an upper end of the second lower sand tank; a drive unit performing squeezing using the upper plate and the lower plate; an adjustment drive unit moving the first lower sand tank; a first detector detecting a height position of the first lower sand tank; a second detector detecting a height position of the second lower sand tank; and a control unit operating the drive unit and the adjustment drive unit so that the height positions of the first communication port and the second communication port coincide with each other, based on detection results of the first detector and the second detector.

Abstract: An induction furnace assembly comprising a chamber having a mold; a primary inductive coil coupled to the chamber; a layered susceptor comprising at least two layers of magnetic field attenuating material surrounding the chamber between the primary inductive coil and the mold to nullify the electromagnetic field in the hot zone of the furnace chamber.

Abstract: A process for directional solidification of a cast part comprises energizing a primary inductive coil coupled to a chamber having a mold containing a material; generating an electromagnetic field with the primary inductive coil within the chamber, wherein said electromagnetic field is partially attenuated by a susceptor coupled to said chamber between said primary inductive coil and said mold; determining a magnetic flux profile of the electromagnetic field after it passes through the susceptor; sensing a component of the magnetic flux in the interior of the susceptor proximate the mold; positioning a mobile secondary compensation coil within the chamber; generating a control field from a secondary compensation coil, wherein said control field controls said magnetic flux; and casting the material within the mold.

Abstract: A continuous casting device having multi-stage convergence control is disclosed. Cooling surfaces of the continuous casting device can be articulated in stages, providing individual convergence control to longitudinally spaced-apart regions of the casting cavity. In a proximal region, during which the molten metal exhibits solidification shrinkage, a first convergence profile can be used to optimally account for the solidification shrinkage. In a subsequent distal region, a second convergence profile can be used, such as to provide optimal control of exit temperature of the continuously cast article. Multi-stage convergence control can be achieved through individually articulatable cooling pads or other supports positioned opposite the cooling surfaces from the casting cavity to displace the cooling surfaces and thereby adjust the convergence profile of the casting cavity.

Abstract: An injection assembly for a die-casting machine includes an injection piston for which a desired speed (Vset) is defined during a metal injection step. The piston is moved by an injection delivery valve and an injection drain valve, controlled in opening according to a tuning speed (Vreg). A system of auto-tuning of the opening of the valves is provided. The tuning speed (Vreg) is determined according to the difference between the desired speed (Vset) for the piston and an effective speed (Veff) of the piston, detected for the previous die-casting cycle.

Abstract: A high-pressure die casting apparatus including a shot sleeve extending through a first die half to a molding surface, and a plunger received in the shot sleeve is provided. The shot sleeve includes a side wall presenting a fluid passageway and a partial end wall disposed in a fixed position relative to the side wall. The partial end wall defines a wall opening adjacent the molding surface. Fluid is poured into the shot sleeve while the die apparatus is open, and the partial end wall prevents the fluid from flowing out of the shot sleeve. The plunger then presses the material into the mold cavity until only a portion of the material remains in the shot sleeve and blocks the wall opening. After the solidified material is ejected from the apparatus, the portion of material blocking the wall opening prevents lubricant from entering the shot sleeve.

Abstract: A casting apparatus for producing castings using molds each having a sprue, comprising a mold-conveying means for conveying molds each containing a melt poured through the sprue; nozzles each having a gas-introducing opening attachable to and detachable from the sprue; nozzle-attaching/detaching means each moving each nozzle to attach and detach the gas-introducing opening to and from the sprue; moving means for moving the nozzle-attaching/detaching means, such that the nozzle-attaching/detaching means moves following a mold conveyed by the mold-conveying means, while keeping the connection of the gas-introducing opening to the sprue by the nozzle-attaching/detaching means; and a gas supply means connected to each nozzle for supplying a gas to the gas-introducing opening.