Abstract: An apparatus and process for manufacturing a disc rotor made of a metal-based composite material, which enables stabilization of a preform support within a disc rotor casting cavity while minimizing likelihood of damaging of preforms. The apparatus comprises a lower die 10 and a movable core assembly 20 which constitutes a disc rotor casting cavity 18; a preform supporting portion 24a which is provided on a movable core assembly 20; a pressurizing and shaping portion 32 of an upper die 30 for applying pressure upon a molten metal accommodated in the cavity 18; and a preform biasing mechanism 40 having a biasing face 41b which can be brought into a face-to-face contact with the upper face of a preform 5 which is supported on the preform supporting portion 24a. On application of pressure upon the molten metal, the preform biasing mechanism 40 biases the preform 5 via the biasing face 41b to prevent the preform 5 from being shifted due to an increase in the pressure upon the molten metal.

Abstract: In a method of manufacturing a plurality of coil-shaped thin cast strips while molten metal r is being supplied to the molten metal pool 3 formed by a pair of cooling drums 1, 1 and a pair of side dams, when a casting operation corresponding to one coil of the coil-shaped thin cast strip has been completed, gas is made to blow from the gas nozzles 7b toward the scum s floating on the molten metal, so that the scum s drifts, due to the gas flow to one meniscus m2, and the thus drifted scum is attached to a surface of the cast strip and circumferential faces of the cooling drums and is then discharged from the molten metal pool.

Abstract: An apparatus (10) and a method for reducing inclusions, shrinkage blowholes, porosity and segregation in metal castings during the casting process, and for improving the grain structure, mechanical properties and yield of ingots and other castings. The apparatus (10) comprises: At least one electrode (14) for forming a moving electric arc (16) over the upper surface (18) of a metallic casting (12) being cast and a stand (20) for suspending the electric arc electrode (14) over the upper surface (18) of the metallic casting (12) during or after pouring and a second electrode (24) attachable to a metallic surface (26) of the mold (28) being used for casting, for completion of an electric circuit (30) including the electric arc (16) and electronic controls (32) connected between the apparatus (10) and a power supply (34).

Abstract: A multiple ignition source exothermic reaction mold device. The mold device includes a crucible in a block with an open top for receiving exothermic reaction powder. A lid covering the open top has an opening therethrough. A receptacle in the lid is in communication with the opening so that the receptacle receives starting powder. The starting powder and, in turn, the exothermic weld material is ignited by alternate sources, either by a spark from an ignitor device or by an electric supply sent through an ignitor element.

Abstract: A molten metal containment device between the crystallizing rollers (38, 39) of a continuous casting machine comprises a lateral containment plate (47) able to press against the shoulder surfaces (40, 41) of the crystallizing rollers (38, 39); means of providing pressure (37) able to move said lateral containment plate (47) so as to move it close to and press it against said shoulder surfaces (40, 41). The lateral containment plate (47) is fixed to the means of providing pressure (37) through an articulated joint which comprises a flexible tubular sleeve (1), corrugated like bellows and able to support said lateral containment plate (47) allowing the horizontal pivoting at least around one axis of pivoting (X) horizontal and not parallel to the axes of rotation (A1, A2) of the rollers (38, 39). In a second aspect of the invention the containment plate (47) is fixed to the means of providing pressure (37) through more supports (20).

Abstract: A mould for continuously casting metal strips comprises a pair of side walls (11) on opposite sides of an open-ended mould cavity (C) having an entrance end (E) for continuously receiving molten metal and an exit end (D) for continuously discharging a moving solidified strip (D) formed from the molten metal. Each mould side wall (11) includes a graphite block (13) formed of a stack of a multiplicity of elongate graphite laminae (16) having opposite faces (16A) and inner edges (16B), said inner edges (16B) jointly forming a surface (16A) directed toward the mould cavity (C). The mould further comprises a cooling system associated with each graphite block (13) and including coolant tubes (15) extending through the stack transversely to said opposite faces (16A) of the graphite laminae (16) forming the stack.

Abstract: The invention provides a termination for a wire rope made by a process of inserting one end of a wire rope into a mold and placing a crucible with a crucible opening over the mold. The mold opening is in fluid communication with the crucible opening. Exothermic metallic material is added to the crucible. The exothermic metallic material is ignited forming a molten material. The molten material flows into the mold around the wire rope forming a termination capable of sustaining a higher break force than the wire rope. The invention also provides a termination for a wire rope made by a process with an adhesive. The termination provides a socket for connecting wire rope to various types of equipment. The socket can include one or more frustroconical wedges for securely holding the wire rope and the termination in the connector. The socket body can also include a protection sled and various ways to connect to the equipment.

Abstract: A method for investment casting includes the steps of positioning a base plate relative to a die; molding a first material between the die and at least a first surface portion of the base plate; securing one or more patterns to the base plate, the one or more patterns comprising a second material; applying one or more coating layers over at least portions of the one or more patterns and at least a portion of the first material; substantially removing the first material through an interior receptacle of a manifold body and the second material through an exterior receptacle of the manifold body to leave one or more shells formed by the coating layers; removing said base plate; introducing molten metal to the one or more shells through the interior receptacle of the manifold body; permitting the molten metal to solidify; and destructively removing one or more investment casting molds.

Abstract: The method for making a termination for a wire rope entails inserting a first end of the wire rope end into a mold, wherein the mold comprises a mold opening; placing a crucible on the mold, adding a separator to the crucible over an opening in the crucible, adding an exothermic metallic material to a crucible, igniting the exothermic metallic material to form a molten material that liquefies the separator; flowing the liquefied separator onto the end of the wire rope forming a termination capable of sustaining a higher break force than the wire rope. Other embodiments of the method entail using a liquid adhesive to form the termination.

Abstract: In a motor drive injection unit and a motor drive injection method, which can obtain an injection speed suitable for a molding material having fast solidifying speed as well as can securely carry out pressure keeping for a predetermined period of time while making a position of an injection piston unmovable after injection and filling are completed, a molding material in a cylinder is injected into a metal mold by converting a rotational motion of an electric servo motor into a reciprocating motion of an injection piston in the cylinder through a plunger with a ball screw, a surge pressure control means is provided for placing the injection piston in the cylinder in an unmovable state when at least a predetermined amount of a load is applied to the injection piston by the molding material in the cylinder, the surge pressure control means includes a combination of rotation control means of the electric servo motor and an upward movement suppression mechanism of the injection piston, and further, an injection s

Abstract: A die cavity of a casting die, such as for continuously casting billets, blooms and blanks. The die cavity has a cross-section with a partially curved peripheral line, whereby, with the cavity walls cooled, provides improved heat exchange between a forming strand shell and the die cavity wall, thus avoiding solidification defects in the strand shell. The degree of curvature 1/R is reduced at least on part of the curved peripheral line of the corner regions from peripheral lines of the same corner regions, that are successive in the casting direction, and at least over part of the length of the die, in the concave corner regions of the die cavity, in order to control the targeted closure of the gap between the strand shell and the cooled die cavity, or a targeted strand shell deformation.

Abstract: Pre-molding of wax or similar sacrificial material over one or more cores facilitates a subsequent molding over a core assembly. Individual cores or groups thereof may be pre-molded in a wax body. One or more such wax bodies may be assembled with other bodies and/or other cores to facilitate a main wax molding of such assembly.

Abstract: A method of forming a material includes the steps of: vibrating a molten material at an ultrasonic frequency while cooling the material to a semi-solid state to form non-dendritic grains therein; forming the semi-solid material into a desired shape; and cooling the material to a solid state. The method makes semi-solid castings directly from molten materials (usually a metal), produces grain size usually in the range of smaller than 50 ?m, and can be easily retrofitted into existing conventional forming machine.

Abstract: The preferred embodiment of the present invention is a die casting apparatus and method evidencing increased apparatus output including the ability of using multiple die tools. The invention includes an indexing assembly removably engaged with at least one die block assembly for transporting between four stations, including an injection station, a cooling station, an ejection station, and a recovery station. The injection station includes a frame, a clamp assembly attached to the frame for clamping and releasing the die block assembly, a shot sleeve assembly engaged with the die block assembly for receiving molten material, such as metal, from a furnace means and injecting the molten material into the die block assembly, and a shot cylinder releasably coupled with the shot sleeve assembly for controlling the injection of molten material.

Abstract: A die casting machine capable of reducing the pressure in a die cavity to a lower level such as a substantially perfect vacuum, having a movable die and a fixed die, a vacuum pump for reducing pressure in a cavity formed between the dies, and an injection apparatus for injecting and filling molten metal into the cavity with reduced pressure, at least one of the dies having an evacuation path connected with the vacuum pump and communicated with the cavity, a valve element for opening and shutting the evacuation path, and an electromagnetic driving means for making the valve element move linearly in the opening and shutting direction by electromagnetic force.

Abstract: A lubricant oil feeder 2 of a due casting machine 1 is made up of a lubricant oil feed passage 19 for feeding a lubricant oil into a clearance between the inner peripheral surface of a sleeve 7 and the outer peripheral surface of an injection piston 9, a lubricant oil feed valve 20 for opening or closing the lubricant oil feed passage, an air feed passage 16 for feeding air into a clearance between the inner peripheral surface of the sleeve and the outer peripheral surface of the injection piston, and an air feed valve 18 for opening and closing the air feed passage, and the arrangement is such that the lubricant oil feed valve is initially opened to feed the lubricant oil into the clearance between the sleeve and the injection piston and the air feed valve is then opened to pump the lubricant oil by the air. It is possible to spread the lubricant oil extensively and quickly, and accordingly, the useful life of the sleeve and the injection piston can be improved with a reduced quantity of lubricant oil.

Abstract: A method is provided for removing a fugitive pattern, such as wax or other meltable pattern material, residing inside of a refractory mold by discharging condensable vapor such as steam inside the mold to contact and melt the pattern while an exterior of the mold is subjected to a non-condensing gas atmosphere such as air outside of the mold wherein the condensable vapor inside the mold and the atmosphere outside of the mold are at substantially the same pressure. Condensable vapor is condensed inside the mold where the vapor has contacted the pattern while the exterior of the mold remains free of condenate. The condensed vapor and melted pattern material are drained out of the mold. The condensed vapor can be discharged initially inside a hollow sprue of a fugitive pattern assembly to melt the sprue and then inside the mold to melt the patterns of the pattern assembly.

Abstract: The invention relates to a hot-top mold for a strand casting apparatus, consisting of a hot-top, which lies on the upper side of a parting agent distributor and presses it with its underside against the surface of a mold, an overhang being formed on the radially inner surface of the hot-top, which protrudes beyond the parting agent distributor in the direction of take off of the strand, the hot-top being centered and held by an outer ring, which is releasably fastened to the mold. The mold surrounds a function ring toward the bearing surface of the mold which, together with the parting agent distributor, forms function surfaces with adjustable roughness on the surfaces. In the parting agent distributor, radial channels are formed at the upper side and the underside, the channel cross sections at the upper side and the underside being in a ratio of 1:3 to 1:5 to one another.

Abstract: In order to more effectively utilise seed crystals 35, 55 to achieve a single crystal grain orientation for a component without the problems of utilising a helix constriction previously necessary to avoid epitaxial grain competition and growth. The present invention creates a wax component pattern 30. This pattern 30 comprises integral sections of wax for a mould component section and for a spacer section with the seed crystal 35 or holder for that crystal therebetween. This pattern 30 is then utilised in order to form a final refractory mould within which the component is formed. By appropriate choice of the spacer section 32, an appropriate spacing between an upper surface of the seed 55 which will be the initial interface with molten castable material to form the component and a chiller surface through which heat is transferred can be determined in order to achieve successful transfer of the seed 55 orientation to the formed component.

Abstract: The apparatus and a method are used to produce metal fiber, which can increase production efficiency of metal fiber using a metal plate and simplify manufacturing equipments and includes a controlling device. The method for producing metal fiber includes steps of: making a frame in a vacuum condition by removing the air; vertically inserting an end of a metal plate between the two induction coils arranged horizontally at an interval in the inside of the frame and heating and melting the end of the metal plate with heat generated by the induction coils; gradually moving the metal plate downwardly and bringing the end of the metal plate into contact with blades of a rotary disk, the rotary disk being horizontally mounted at a lower portion of the induction coils in the inside of the frame and rotating in a high speed; and solidifying metal fiber separated by the blades of the rotary disk.