Patents Examined by Kevin P. Kerns
  • Patent number: 10975700
    Abstract: A turbine blade designing method is for designing a turbine blade formed using a metal material in which creep including diffusion creep and dislocation creep occurs by heating. The turbine blade designing method includes: acquiring temperature distribution data relating to temperature distribution in the turbine blade to be heated; acquiring creep strength distribution data relating to distribution of the creep strength required for the turbine blade to be heated; from the correlation data, based on the temperature distribution data and the creep strength distribution data, setting the crystal grain size of a high-temperature portion that is the diffusion creep temperature range of the turbine blade to a size coarser than the reference crystal grain size, and setting the crystal grain size of a low-temperature portion that is the dislocation creep temperature range of the turbine blade to a size finer than the reference crystal grain size.
    Type: Grant
    Filed: August 22, 2016
    Date of Patent: April 13, 2021
    Assignee: MITSUBISHI HEAVY INDUSTRIES, LTD.
    Inventors: Hideaki Kaneko, Kenji Yamamoto, Takanori Karato, Norifumi Hirata, Naoya Fujita
  • Patent number: 10974319
    Abstract: In a casting device, positions of discharge ends discharging cooling gas, of respective gas supply nozzles are adjusted in response to movement of a mold. This makes it possible to stably achieve high cooling performance for the mold by blowing of the cooling gas. To adjust the positions of the respective discharge ends, the gas supply nozzles are advanced or retreated, or are expanded or contracted. Further, a cooling chamber may include a radiation cooling portion that cools the mold by radiation, and the radiation cooling portion is disposed below the gas supply nozzles that are provided directly below a heat shielding body partitioning a heating chamber and the cooling chamber.
    Type: Grant
    Filed: March 9, 2017
    Date of Patent: April 13, 2021
    Assignee: MITSUBISHI HEAVY INDUSTRIES, LTD.
    Inventors: Takeshi Kaneko, Masaki Taneike, Hidetaka Oguma
  • Patent number: 10974318
    Abstract: A CAE analysis die model is produced such that a cavity of a die for obtaining a cast product is divided into multiple elements. Fluidity analysis and solidification analysis are performed under a predetermined casting condition by means of the die model to calculate, for each element, a factor regarding growth of a solidification structure, a factor regarding purity of molten metal, and a factor regarding a hole defect. Mechanical characteristics of each portion of the cast product are obtained by a regression expression obtained by multiple regression analysis using mechanical characteristics of the cast product as an objective variable and using each factor as an explanatory variable.
    Type: Grant
    Filed: November 20, 2018
    Date of Patent: April 13, 2021
    Assignee: MAZDA MOTOR CORPORATION
    Inventors: Koji Takemura, Ichiro Kouno, Shohei Fujii, Shohei Hanaoka
  • Patent number: 10974312
    Abstract: A method of forming a cast component and a method of forming a casting mold is provided. The method is performed by connecting at least one wax gate component to a ceramic core-shell mold. The ceramic core-shell mold includes at least a filter, a first core portion, a first shell portion, and at least one first cavity between the core portion and the first shell portion. The ceramic core-shell mold may be manufactured using an additive manufacturing process and may include an integrated ceramic filter. At least a portion of the ceramic core-shell mold and the wax gate component is coated with a second ceramic material. The wax gate component is then removed to form a second cavity in fluid communication with the first cavity.
    Type: Grant
    Filed: June 28, 2017
    Date of Patent: April 13, 2021
    Assignee: GENERAL ELECTRIC COMPANY
    Inventors: Xi Yang, Michael Cole, Michael Brown, Gregory Terrence Garay, Tingfan Pang, Brian David Przeslawski, Douglas Gerard Konitzer
  • Patent number: 10974316
    Abstract: A secondary cooling method and a secondary cooling device for a casting product casted in a continuous casting machine, the continuous casting machine including, in a secondary cooling zone below a mold, a plurality of pairs of support rolls that support the casting product from both sides of the casting product in a thickness direction, a cooling device being disposed between support rolls adjacent to each other along a casting direction of the continuous casting machine, the cooling device including a coolant pipe that supplies a coolant, and a coolant guide plate with a flat plate shape for spreading the coolant on the casting product, the coolant guide plate being disposed parallel to and spaced in a perpendicular direction from a surface of the casting product.
    Type: Grant
    Filed: January 27, 2017
    Date of Patent: April 13, 2021
    Assignee: NIPPON STEEL CORPORATION
    Inventors: Yuki Kuwauchi, Hitoshi Funagane, Satoru Hayashi
  • Patent number: 10967426
    Abstract: An injection device of light metal injection molding machine and an injection control method thereof are provided, in which a melt in a supply unit is supplied into an injection unit through a communication passage, a plunger of the injection unit is retracted to measure the melt, the communication passage is closed, and the plunger is advanced to inject the melt into a mold device through an injection nozzle of the injection unit. After the injection and before the measurement, the plunger is advanced under a pressure at which the melt does not come out from the injection nozzle to make the melt in the injection unit flow back into the supply unit through the opened communication passage.
    Type: Grant
    Filed: October 3, 2019
    Date of Patent: April 6, 2021
    Assignee: Sodick Co., Ltd.
    Inventor: Misao Fujikawa
  • Patent number: 10967425
    Abstract: A continuous steel casting method includes producing a strand. The producing of the strand includes pouring molten steel into a mold of a continuous casting machine and withdrawing a solidified shell from the mold, the solidified shell being a solidified portion of the molten steel. The method includes applying a static magnetic field to at least a portion of a region of the strand, the strand being in the continuous casting machine, the region being a region where a solid fraction fs at a thickness-wise middle position of the strand is in a given range, the static magnetic field having a magnetic field strength of greater than or equal to 0.15 T and being in a direction orthogonal to a direction in which the strand is withdrawn, the static magnetic field being applied at an application time ratio of greater than or equal to 10%.
    Type: Grant
    Filed: March 29, 2017
    Date of Patent: April 6, 2021
    Assignee: JFE Steel Corporation
    Inventors: Tomoya Odagaki, Norichika Aramaki, Yuji Miki, Naoki Kikuchi
  • Patent number: 10960464
    Abstract: Disclosed are a method of casting heterogeneous materials and a casting produced manufactured by the same. The method may include disposing a lost foam on a cavity of a mold as the cavity being formed in a shape corresponding to a shape of a casting product; injecting a first molten metal through a low-pressure molten metal ingate formed in the mold to form a low-pressure casting portion of the casting product; and injecting a second molten metal through a gravity molten metal ingate formed in the mold to form a gravity casting portion of the casting product.
    Type: Grant
    Filed: November 18, 2019
    Date of Patent: March 30, 2021
    Assignees: Hyundai Motor Company, Kia Motors Corporation
    Inventor: Jinkwan Kim
  • Patent number: 10960461
    Abstract: In one embodiment, a lead strip caster for battery grids includes a ladle, a nozzle, and a pair of rollers. The lead strip caster produces a continuous lead strip for use as battery positive plate grids. The ladle has an inlet to receive molten lead and has an outlet. The nozzle has at least one passage that communicates with the outlet of the ladle in order to receive molten lead from the ladle. The first roller is situated at a first exterior side of the nozzle. The first roller rotates via a first driver. The second roller is situated at a second exterior side of the nozzle. The second roller rotates via a second driver.
    Type: Grant
    Filed: September 13, 2017
    Date of Patent: March 30, 2021
    Assignee: Wirtz Manufacturing Co., Inc.
    Inventor: Michael Romeo
  • Patent number: 10960460
    Abstract: A mold for manufacturing a casted workpiece is, at least in-part, manufactured utilizing an additive manufacturing process. The mold may have a core having non-line-of-sight features that are additively manufactured and in contact with an outer shell of a wax mold and/or an outer shell of a casting mold of the mold. The outer shell of either the wax or casting molds may also be additively manufactured, and the shell of the casting mold may be additively manufactured as one unitary piece to the core.
    Type: Grant
    Filed: January 23, 2015
    Date of Patent: March 30, 2021
    Assignee: Raytheon Technologies Corporation
    Inventors: Brooks E. Snyder, Thomas N. Slavens, Mark F. Zelesky, James T. Auxier
  • Patent number: 10957942
    Abstract: In one embodiment, a lead strip caster for battery grids includes a nozzle, a pair of rollers, and a molten lead supply to the nozzle. The lead strip caster produces a continuous lead strip for making battery grids. The nozzle has at least one passage that communicates with generally opposed faces of the nozzle at least partially received between the rollers to supply molten lead to exterior surfaces of the corotating rollers to form a continuous solid strip of lead from which battery grids may be made.
    Type: Grant
    Filed: July 30, 2018
    Date of Patent: March 23, 2021
    Assignee: Wirtz Manufacturing Co., Inc.
    Inventor: Michael R. Romeo
  • Patent number: 10953463
    Abstract: In a casting device, when a mold varied in outer size depending on a position passes through a heat shielding portion between a heating chamber and a cooling chamber, a flexible portion of a heat shielding body is bent to fit the outer size of the mold.
    Type: Grant
    Filed: March 9, 2017
    Date of Patent: March 23, 2021
    Assignee: MITSUBISHI HEAVY INDUSTRIES, LTD.
    Inventors: Takeshi Kaneko, Masaki Taneike, Hidetaka Oguma
  • Patent number: 10953461
    Abstract: An investment casting method includes providing a stock investment casting core, bending the stock investment casting core to thereby form a production investment casting core that conforms to a design cooling passage shape, and casting an alloy around the production investment casting core to form a cast article.
    Type: Grant
    Filed: March 21, 2019
    Date of Patent: March 23, 2021
    Assignee: RAYTHEON TECHNOLOGIES CORPORATION
    Inventors: Steven D. Porter, Jon E. Sobanski
  • Patent number: 10953462
    Abstract: An investment casting model for the creation of a mold for investment casting of a plurality of objects, the investment casting model being realized in solidifiable resin, and includes: a base defining a Z axis; a plurality of wire-like elements all extending from the base, the wire-like elements intersecting each other to form a plurality of simple closed curves, which form a net around the Z axis. At least two of the simple closed curves of the plurality are identical to each other and the net includes: at least a first and a second sets of simple closed curves, each set forming a net sub-structure around the Z axis, the second set being adjacent to the first set along the Z axis; a plurality of object models; and a plurality of connecting branches joining the plurality of object models to the wire-like elements forming the net.
    Type: Grant
    Filed: January 16, 2020
    Date of Patent: March 23, 2021
    Assignee: DWS S.R.L.
    Inventor: Sergio Zenere
  • Patent number: 10946437
    Abstract: Systems and methods for making aluminum alloy products are described including those that decrease the tendency for hot tearing or shrinkage porosity to occur during casting by introducing forced convection during the casting process. The forced convection may result in formation of high circularity grains during the solidification process, thereby increasing the permeability of the liquid aluminum alloy and decreasing the tendency for hot tearing or shrinkage porosity to occur.
    Type: Grant
    Filed: February 12, 2020
    Date of Patent: March 16, 2021
    Assignee: NOVELIS INC.
    Inventors: Samuel Robert Wagstaff, Kathleen Anna Bennett, Elli Taylor Tindall
  • Patent number: 10946439
    Abstract: The application provides a plaster casting mold fabrication method for a complicated structure aluminum alloy casting with a large inner cavity and a thin wall, in which, a wax pattern is cleaned with a mixture; closed blind cavity and large plane unbeneficial to plaster mold-filling of the wax pattern are used to exhaust air by using vent holes and waterproof-breathable membranes in cooperation with each other; under pressure difference, plaster powder and mixed aqueous solution are vertically splashed and mixed in a mixing tank to reduce dust discharge; asynchronous mixing and grouting can be realized by left and right mixing tanks in an upper tank of a vacuum tank. The present application can effectively remove the surface parting agent, increase the wettability of the plaster paste and the wax pattern surface, and improve the surface finish of the casting mold.
    Type: Grant
    Filed: December 5, 2019
    Date of Patent: March 16, 2021
    Assignee: No.59 Institute of China Ordnance Industry
    Inventors: Qiang Chen, Yuanyuan Wan, Zhihui Xing, Gaozhan Zhao, Jianquan Tao, Zhiwei Huang, Ming Li, Yanbin Wang, Shuxin Chai, Hong Zhan, Maochuan Wang, Xiaohui Lin
  • Patent number: 10946438
    Abstract: A system for casting a length of a pole of a tubular shape with molten metal. The system comprises a crucible for containing the molten metal; a pouring spout fluidly connected to the crucible; and a plunger for plunging in the crucible to increase level of the molten metal in the crucible and thereby forcing a flow of the molten metal from the crucible to the pouring spout. The system further comprises a casting ring for receiving the molten metal poured out of the pouring spout; a motor for rotating the casting ring; a cooling assembly for cooling the molten metal; and a pulling assembly for pulling the pole out of and away from the casting ring as the molten metal solidifies.
    Type: Grant
    Filed: March 5, 2018
    Date of Patent: March 16, 2021
    Assignee: 8617490 Canada Inc.
    Inventors: Luc Montgrain, Jean-Fran├žois Desmeules, Olivier Dion-Martin
  • Patent number: 10940530
    Abstract: A method of manufacturing a heat shield panel assembly is provided. The method including: forming a heat shield panel, wherein the heat shield panel includes one or more orifices; and forming each of one or more threaded studs through operations including: injecting melted wax into a negative cavity of a threaded stud; allowing the wax to solidify to form a positive pattern of the threaded stud; removing the positive pattern of the threaded stud from the negative cavity of the threaded stud; coating the positive pattern of the threaded stud with a ceramic; melting the positive pattern of the threaded stud away from the ceramic, the ceramic having a second cavity forming a second negative cavity of the threaded stud; pouring melted metal into the second cavity; allowing metal in the second cavity to solidify to form the threaded stud; and removing the ceramic from the threaded stud.
    Type: Grant
    Filed: September 12, 2017
    Date of Patent: March 9, 2021
    Assignee: RAYTHEON TECHNOLOGIES CORPORATION
    Inventor: John Joseph Marcin
  • Patent number: 10940529
    Abstract: A method of manufacturing a heat shield panel assembly is provided. The method including: injecting melted wax into a negative cavity of a heat shield panel, the heat shield panel including one or more orifices; allowing the wax to solidify to form a positive pattern of the heat shield panel; removing the positive pattern from the negative cavity; coating the positive pattern with a ceramic; melting the positive pattern away from the ceramic, the ceramic having a cavity forming a second negative cavity of the heat shield panel; pouring melted metal into the cavity; allowing metal in the cavity to solidify to form the heat shield panel; removing the ceramic from the heat shield panel; and forming each of one or more threaded studs separately from the heat shield panel, each of the one or more threaded studs including a stud portion and a thread portion simultaneously formed.
    Type: Grant
    Filed: September 12, 2017
    Date of Patent: March 9, 2021
    Assignee: RAYTHEON TECHNOLOGIES CORPORATION
    Inventor: John Joseph Marcin
  • Patent number: 10940531
    Abstract: Methods of improving a surface finish of a casting pattern for an investment casting process, methods of forming an investment casting, and smoothed casting patterns. The methods for forming the casting patterns having an improved surface finish include sealing the casting pattern with a first coating material to form a sealed casting pattern and smoothing the sealed casting pattern with a second coating material to form a smoothed casting pattern. The methods for forming the investment casting include covering a smoothed casting pattern with a mold material to define an enclosed mold volume, curing the mold material to form a cured mold material, flowing the smoothed casting pattern from the enclosed mold volume to define a void space, filling the void space with a liquid investment casting material, and solidifying the liquid casting material to define an investment casting.
    Type: Grant
    Filed: October 31, 2019
    Date of Patent: March 9, 2021
    Assignee: The Boeing Company
    Inventors: Elaine MacDonald, Daniel Joseph Braley, Brandon Heath Wegge, Russell W. Cochran