Abstract: A parent bore cylinder block of an internal combustion, opposed-piston engine includes cooling passages that are formed using a 3-D printed casting core. The casting core can include portions that are ceramic. The parent bore cylinder block can include multiple cylinders, each cylinder with cooling passages and turbulence inducing features in those cooling passages, particularly surrounding the central portions of the cylinders.

Abstract: Foundry casting elements and methods of forming the same, the methods including: forming an aqueous slurry including an inorganic binder precursor, shaping the slurry using a pattern, curing the shaped slurry using a low temperature solidification process to form a casting element, and removing the pattern from the casting element.

Abstract: A cooling insert for a die, such as a distributor for a high pressure die casting assembly, and a method of manufacturing the cooling insert, is provided. The cooling insert can be formed of H13 tool steel and is manufactured using an investment casting process, for example, a process which uses a printed investment casting shell. The cooling insert includes complex cooling channels to improve cooling and reduce the duration of the casting process.

Abstract: An automated guided vehicle (AGV) including a frame, ground-contacting elements connected to the frame for supporting the AGV and a heat shield is used in an automated sow casting facility. AGVs are adapted to get hold of, to move and to release moulds used for producing sows. A method of operating the casting facility involving AGVs to move moulds between stations is also described.

Abstract: An electric squeeze device is provided and includes: an electric squeeze device includes: a squeezing frame that applies a pressurizing force to the casting sands, a swing arm that is positioned on an upper side of the squeezing frame and reciprocates at a predetermined angle with respect to a rotation center; a link having one end side connected to a position of a radius of rotation A from the rotation center O of the swing arm and another end side connected to the squeezing frame; a driven gear formed along a virtual arc of a radius of rotation B from the rotation center of the swing arm; a drive gear that meshes with the driven gear; and an electric motor that rotationally drives the drive gear.

Abstract: A new method of manufacturing a dual investment reticulated solid mold for producing reticulated metal foam, that includes 3D printing of a wax or resin reticulated precursor prior to pre-investment with a pre-investment plaster or pre-investment ceramic plaster, and removal of the precursor before addition of liquid metal to generate reticulated metal foam.

Abstract: The present invention relates to methods for forming bonded particulate refractory materials for use in metal-working, comprising the steps of providing a fine particulate metal oxide, providing an aqueous alkaline composition, providing a particulate refractory mould material, mixing the said fine particulate metal oxide, the said aqueous alkaline composition and the said particulate refractory mould material, and shooting the obtained mixture in a core shooter. Substantially all the water included in the obtained mixture is derived from the aqueous alkaline solution and optionally the surfactant. Also part of the present invention are materials and articles obtained according to the method, as well as particulate compositions for use in the method.

Abstract: A thermally stable component formed of a tempered aluminum alloy casting which reduced costs is provided. The aluminum alloy typically has an elongation of at least 8% after casting, which is preferred for self-piercing rivet processes. The aluminum alloy leaves a casting facility in the as-cast (F temper) condition. The cast aluminum alloy is then shipped to another entity, such as an OEM, and is subjected to an artificial aging process, such as on the OEM's existing paint line, rather than at the casting facility. The artificial aging process typically includes electrodeposition coating and curing. The components that can be formed by the reduced cost method include lightweight automotive vehicle components, including structural, body-in-white, suspension, or chassis components, such as front shock towers, front body hinge pillars, tunnels, and rear rails.

Abstract: A continuous casting method of steel of continuously casting a slab by using a vertical liquid bending type continuous casting machine. The method includes, while performing continuous casting by using an in-mold electromagnetic stirring device, applying an alternating-current moving magnetic field that moves in a width direction of a mold to molten steel inside the mold, inducing a swirling flow in the molten steel, and stirring the molten steel. A travel speed of the alternating-current moving magnetic field calculated by a specified formula is in a range of 0.20 to 1.50 m/s.

Abstract: Lost wax casting bonding methods and systems. A method for bonding a wax component in a feeder system for a lost wax casting process comprises embedding conductive nano-particles in wax to form a sacrificial susceptor. The method includes coupling the wax component to another component such that the sacrificial susceptor is at an interface of the wax component and the other component. The method comprises inductively heating the sacrificial susceptor to cause the wax of the sacrificial susceptor and at least a portion of wax of the wax component to melt to thereby form a bond between the wax component and the other component.

Abstract: A system of detection of a temperature of a crystallizer or a level of liquid metal in the crystallizer has a sensor positioned within a mould of the crystallizer. The sensor has a case, a closing cover positioned at a detection face of the case, a plurality of ultrasonic elements arranged in vertically spaced relation to a length of the case, and a plurality of attenuation elements positioned sideways with respect to the closing cover. The plurality of ultrasonic elements include a first ultrasonic element, a second ultrasonic element and a third ultrasonic element positioned in orthogonal relation to the length of the sensor. The plurality of ultrasonic elements transmit and receive ultrasonic waves.

Abstract: A molding system for a low-pressure light alloy casting plant, extending in height along a main axis, has a mold having a lower half-mold and an upper half-mold. The molding system has a first lower fixed plate on which the lower half-mold is housed, a movable plate on which the upper half-mold is housed, a second upper fixed plate positioned at the top of the movable plate, a movement group for moving the movable plate along the main axis, having an electric drive motor and transmission members operatively connected to the electric drive motor and to the movable plate, a casting ejection group having an electric ejector motor and ejection members movable by the electric ejector motor in an ejection position in which the casting is detached from the upper half-mold, and a command unit controlling operation of the electric drive motor and of the electric ejector motor.

Abstract: Device and method for injection moulding a metal alloy intended for manufacturing at least one part made of an amorphous metal alloy or metallic glass, wherein: an injection mould (2) delimits a cavity that has a receiving face (4) and a frontal moulding face (5) opposite the receiving face, at least one sacrificial shaping insert (7) is placed in said cavity and has a rear face (8), at least one contact zone of which is adjacent to at least one contact zone of said receiving face of the cavity and a front face (9) that is situated opposite said moulding face of the mould and provided with a recessed shape, and an injection piston (I I) is movable in a chamber (12) of the mould and communicates with the moulding impression.

Abstract: A process for thin strip production integrates continuous casting and rolling, with steps including continuous casting, rough rolling, induction heating, finish rolling, laminar cooling, high-speed shearing, and coiling. A key feature is the in-line heating between casting and rough rolling, where wide surfaces, narrow surfaces, and corners of the casting blank are heated simultaneously. This process improves rough rolling efficiency, enhances uniformity and thickness stability of thin strips, reduces out-of-tolerance rates, and minimizes rolling-induced cracks.

Abstract: A method for producing a vehicle wheel from a light metal material is disclosed herein. The light metal material is introduced in liquid form into a mold cavity of a casting mold and pressurized casting is then used to produce the vehicle wheel. The casting mold is temperature-controlled, where different regions of the casting mold are maintained at different temperatures. An apparatus that includes the disclosed casting mold is also described herein.

Abstract: A casting-rolling side sealing device with an electromagnetic stirring function is provided and includes a pair of side sealing plates covering two side ends of a casting-rolling zone from a casting-rolling starting end to a casting-rolling ending end respectively, a pre-tightening force is formed between one of the side sealing plates and adjacent casting rolls. A pulse end of a first electromagnetic assembly releases first pulses along a first axis direction parallel to a direction from the side ends to a center of the casting-rolling zone. The first pulses are configured to generate an electromagnetic stirring effect in the casting-rolling zone. A second electromagnetic assembly is arranged on each of the side sealing plates, a pulse end of the second electromagnetic assembly releases second pulses along a second axis direction perpendicular to the first axis direction.

Abstract: A low-pressure aluminum casting mold and a low-pressure aluminum casting process for a motor rotor. The low-pressure aluminum casting mold includes an upper blade profile assembly, a lower blade profile assembly, a rotor core, a dummy shaft and a diverter. The upper blade profile assembly includes an upper backing plate and an upper mold, and the lower blade profile assembly includes a lower backing plate and a lower mold. The low-pressure aluminum casting mold further includes a first pressing device and four sets of second pressing devices. The low-pressure aluminum casting process includes the steps of cold lamination, heating of the rotor core, mold preparation, hot lamination, and low-pressure casting.

Abstract: A metal casting system includes a master conveyor, a slave conveyor, a cutting device, and a control system. The master conveyor includes a first belt and a first motor, and the slave conveyor is separated from the master conveyor and includes a second belt and a second motor. The cutting device is between the master conveyor and the slave conveyor and selectively cuts a metal product that is conveyed by the master conveyor and the slave conveyor. The control system includes a sensor that detects ends of sections of the metal product as the sections of the metal product move in a downstream direction. The control system also includes a controller communicatively coupled with the sensor. The controller selectively controls at least one of the first motor or the second motor based on the detected ends from the sensor.

Abstract: A method of forming a directionally-solidified casting component using a casting system is provided. The casting system includes a chamber having a heating zone and a cooling zone separated by a baffle plate. The method includes pouring an alloy in a liquid state into a mold shell. The mold shell is positioned on a chill plate within the heating zone. The method further includes moving the mold shell from the heating zone into the cooling zone. The alloy transfers from the liquid state to a solid state within the mold shell while moving the mold shell from the heating zone to the cooling zone. The method further includes contacting the mold shell with a heat transfer member.

Abstract: A mullite shell mold for casting includes a facecoat layer containing ceramic flour. The mullite shell mold also includes a first layer disposed on the facecoat layer. The first layer can contain sintered ceramic media. The facecoat layer and the first layer can each contain less than 1 wt % crystalline silica.