Abstract: A method and apparatus for the lost pattern casting of metals employs an erodable mold including a particulate material and a binder. An erodable backing or coating may be used to support the erodable mold. After a molten metal casting is poured in the mold, the erodable backing and the mold are contacted with a solvent. This cools the molten metal so that it at least partially solidifies to form a casting. At least a part of the mold is removed. Also, the coating or backing may be removed.

Abstract: In a lubricant composition suitable for use in the manufacture of aluminum alloys comprising lubricant base selected from the group consisting of solid lubricants, liquid lubricants, grease lubricants, emulsion lubricants, and dispersion lubricants, the improvement wherein the lubricant composition further comprises: an effective amount of water and surfactant or water and a compound comprising phosphates, borates, fluorides, and silicates. It is believed that mixing oil with water and surfactant or one of these compounds provides a method for uniformly distributing the surface oxide at the meniscus for casting applications, thereby reducing vertical fold formation that lead to cracks in aluminum ingots. In addition, the mixture promotes uniform heat transfer around the mold allowing the solidifying aluminum alloy to stay in contact with the mold longer and form stronger ingot shells.

Abstract: A fine metal particle producing mechanism has a metal holder for housing a body of magnesium, a tube for supplying an argon gas to the body of magnesium, an argon gas flow rate controller for controlling a rate at which the argon gas is supplied to the tube, and an argon gas heating controller for heating the argon gas supplied to the tube to a predetermined temperature.

Abstract: A mold design is disclosed for sand casting of engine cylinder blocks, such as engine cylinder V-blocks, with cast-in-place cylinder bore liners, wherein a dimensional accuracy in the positioning of cast-in-place bore liners is maximized.

Abstract: A direct pour metal casting process and casting mold having a direct pour passage. The casting mold is filled from a bottom pour ladle that dispenses molten metal into a riser core. The riser core defines an opening that progresses from a circular opening in the top to a slot opening in the bottom of the riser core that is generally shaped as an inverted funnel.

Abstract: A body member and flange members are butted together at first and second abutment portions, and are retained by first and second backing jigs. In this arrangement, inner circumferential surfaces of the first and second abutment portions are fitted on and in close contact with outer circumferential surfaces of the first and second backing jigs. Subsequently, the friction stir welding is performed along each of the first abutment portion and the second abutment portion by using a probe which is rotated at a high speed.

Abstract: Continuously cast products (12) are often provided with surface defects such as oscillation marks (17) and other non-homogeneous structures in the cast state thereof during production in a casting die (11) of a continuous casting plant (10). Defects which render a strip useless for superior applications also frequently occur on the strip surface during subsequent milling of the slab (12?) into a strip. The aim of the invention is to minimize said defects and provide the rolling mill with a slab (12?) having a desired preliminary profile and an improved near-surface structure. Said aim is achieved by arranging a reducing roll stand (30) in the area of the bending rolls or straightening driver rolls (24) within the continuous casting plant (10).

Abstract: Reinforced moulds for a casting machine include a wall for containing a cast article, the wall including a lip region. The lip region includes a reinforcing element cast internally in the lip region. The reinforcing element provides enhanced resistance to tensile tearing and cracking of the moulds. Methods of making and using the reinforced moulds also are provided.

Abstract: An arc welding cable that is resistant to bending and twisting and can give a long life is provided. For this purpose, an arc welding cable (65) for supplying a welding current, a welding wire and a sealed gas from a wire feeding device (61) to a welding torch (64), has a passage (4) for the welding wire (2) and sealed gas is located at a center of the arc welding cable and a plurality of conductors (5) are arranged apart from one another on a circumference around the passage (4). The space between the plurality of conductor (5) may be filled with a cushion material such as cotton or elastic synthetic resin.

Abstract: In a filling-tube construction (1, 2) for providing a connection between a mould (6) to be filled with molten metal and a mould-filling furnace (3) containing molten metal (5), said mould (6) having at least one casting cavity (7), the lowermost part of each such cavity communicating with a filling duct (8), at least one end of which is open to the outside of said mould (6) and adapted to be temporarily connected to the filling-tube construction (1, 2) to receive molten metal (5) from the mould-filling furnace (3), the mould-filling furnace being adapted to contain molten metal (5) and to transfer said molten metal (5) under a controlled pressure through the filling-tube construction (1, 2) and to the filling duct (8), the filling-tube construction comprises a first section (1) extending from a position close to the bottom of said mould-filling furnace (3) up to an intermediate position closer to the filling duct (8) and at least one separate second section (2) providing a connection from the upper end of the

Abstract: A process for the production of a braking band having ventilation ducts comprises the steps of a) moulding a core of metallic material, b) inserting the core in a mould, in a central position, c) filling the mould with at least two layers of material which are to form the braking band, in a manner such that the core is “sandwiched” between the at least two layers, d) performing a first heating of the mould to a temperature such as to bring about hardening of the at least two layers until the at least two layers adopt a three-dimensional structure, e) subjecting the semi-finished product produced in step d) to a second heating to a temperature such as to bring about fusion of the metallic material of the core, and f) collecting the molten core.

Abstract: A distributor device for use in aluminium casting includes a rigid, substantially bowl-shaped receptacle (2) of a refractory material having a base member (4) and a peripheral wall (6) that extends upwards from the base. The receptacle has an inlet opening (8) towards the upper end thereof and a pair of outlet openings (14) towards the base thereof. The device is constructed and arranged such that, in use, molten aluminium poured into the distributor device through the inlet opening (8) is redirected by the distributor device and flows outwards into the mould through the outlet openings (14).

Abstract: A composition and method for forming investment casting shells includes using colloidal silica, zircon flour, and fused silica in a slurry which is applied to a pattern. After the slurry is applied to the pattern, it is allowed to partially or completely solidify. After the shell has solidified, the pattern may be melted or otherwise removed. A molten material is introduced into the shell and allowed to cool to form an article. Finally, the shell is broken away or otherwise removed from the article. The improved shell slurry composition and corresponding method minimizes pattern-to-pour cycle times and is environmentally friendly.

Abstract: The formation of spot welds in high strength steel workpieces is improved by using welding electrodes with annular, or donut shaped welding tips for the formation of the molten metal weld pool at the weld site. The annular poll solidifies to form an annular weld nugget. Preferably the donut shaped nugget has an internal diameter that is no more than three-quarters of the outside diameter. The method is applicable to carbon steel workpieces with allowing elements for strengthening, and to thick sheets of mild carbon steels.

Abstract: A method and apparatus for the lost pattern casting of metals is disclosed. In the method, a pattern is formed from a material and a mold is formed around at least a portion of the pattern. The mold includes a particulate material and a binder. The pattern is removed from the mold and molten metal is delivered into the mold. The mold is contacted with the solvent and the molten metal is cooled such that it at least partially solidifies to form a casting. The step of cooling includes contacting a shell of solidifying metal around the molten metal with the solvent. An apparatus is also disclosed.

Abstract: The purpose of the present invention is to provide a method that can be easily applied to friction stir welding where the thickness of face plates at one welding portion is different from the thickness of face plates at another welding portion. Three shape members 10, 11, 12 having two butt joint portions are mounted on a jig 15. The face plate 14 of shape member 10 is thick and the face plate 14 of shape member 12 is thin. The protruded height of projection 18 is greater at portion B where surface plates 14 being welded are thin than the protruded height of projection A where surface plates 14 are thick. The depths for inserting rotary tools to shape members 10, 11, 12 for friction stir welding are the same. Friction stir welding is facilitated since the size and insertion depth of all the rotary tools being applied can be the same.

Abstract: A method of shaping a semisolid metal comprising pouring a molten aluminum or magnesium alloy which contains a crystal grain refiner and which is superheated to less than 50° C. above a liquidus temperature of aluminum or magnesium, directly into a vessel without using a cooling jig, maintaining the alloy in the vessel for 30 seconds to 30 minutes as a resultant melt is cooled to a temperature where a specified liquid fraction is established such that a temperature of the poured alloy which is liquid and superheated to less than 10° C. above the liquidus temperature or which is partially solid, partially liquid and at a temperature of less than 5° C. below the liquidus temperature decreases from an initial level and passes through a temperature zone 5° C. below the liquidus temperature within at least 10 minutes, whereby fine primary crystals are generated in the alloy, recovering the alloy from the vessel, supplying the alloy into a mold, and shaping the alloy under pressure.

Abstract: An automated matchplate molding machine includes a cope flask, a pattern plate and a drag flask for creating formed sand molds. A lock is provided to lock the drag flask to the platen table of the molding machine during desired stages of an individual sand molding sequence. The lock between the drag flask and the platen table may include actuated pins which engage corresponding detent structures such as tapered holes integral with the drag flask and prevent lateral migration of the drag flask relative to the platen table. Additionally, cope flask actuators are provided which vertically support and are operable to raise the cope flask relative to the squeeze head to facilitate release the cope mold from the cope flask.

Abstract: An apparatus comprising a casting ring and base sized and dimensioned to be coupled together to form a cavity having one or more walls comprising an inner surface of the casting ring, having a bottom comprising an upper surface of the base, and having a form receiving member portion of the base extending into the cavity. This embodiment includes an indicator forming portion sized and positioned to form an indicator on a mold produced by at least partially filling the cavity with investment and allowing the investment to harden. In some instances the casting ring may have a lower segment sized and dimensioned to surround and receive an upper segment of the base to couple the ring and base together, wherein, the casting ring latches onto an outwardly protruding shoulder of the base when the base and casting ring are coupled together.

Abstract: In a lubricant composition suitable for use in the manufacture of aluminum alloys comprising a lubricant base, the improvement wherein the lubricant composition further comprises: an effective amount of water, surfactant, and a high viscosity organic material having a low vapor pressure. It is believed that this mixture provides a method for uniformly distributing the surface oxide at the meniscus for casting applications and increasing meniscus stability. Uniform distribution of the oxide and increased stability at the meniscus reduces vertical fold formation that can lead to cracks in the aluminum ingot. In addition, the mixture promotes uniform heat transfer around the mold. Uniform heat transfer around the mold allows the solidifying aluminum alloy to stay in contact with the mold longer and form stronger ingot shells. A process for continuous or semi-continuous casting of aluminum alloys via the use of this lubricant composition is also disclosed.