Abstract: The present invention: provides a mold for continuous casting that makes it possible to prevent insulation from deteriorating when continuous casting is carried out with electromagnetic force applied to and produce castings of good quality for a long period of time; and is a mold for continuous casting, said mold for continuous casting being equipped with a magnet coil that imposes electromagnetic force on molten metal in the direction perpendicular to the inner wall of said mold in the vicinity of the meniscus of said molten metal in said mold for continuous casting, a pair of the first sets each of which is formed by combining a first cooling copper plate with a first back plate, and another pair of the second sets each of which is formed by combining a second cooling copper plate with a second back plate, and being configured so that a pair of said first sets each of which is composed of a first cooling copper plate and a first back plate are movably interposed between a pair of said second sets each of wh

Abstract: A high field contrast magnetic stamper/imprinter for use in patterning of magnetic and magneto-optical (MO) recording media by contact printing, comprises: (a) a layer of a magnetic material having a high saturation magnetization Bsat?˜1.2 and high permeability ??˜5, including a first, topographically patterned surface and a second surface opposite the first surface, the first, topographically patterned surface comprising a patterned plurality of spaced-apart recesses with a plurality of non-recessed areas therebetween, the topographical pattern corresponding to a magnetic pattern to be formed in a magnetic or MO recording medium; and (b) a layer of Ni on the second surface. A corrosion-resistant protective overcoat layer may be present on the topographically patterned surface. A method for manufacturing the stamper/imprinter is also disclosed.

Abstract: The invention relates to apparatus and methods for forming a terminal on a battery. Terminal forming apparatus (11) has a mould (12) with a cavity (26) which is intended to encircle the post and bush assembly (22, 25) of a battery box (10). The mould cavity (26) is formed with an open upper mouth (27) and a lateral inlet/outlet (28) which connects with the feed channel (13). Inlet (28) is defined by a weir (29) which acts as a constant height device to define the final filling height of the mould cavity (26). This arrangement allows over filling of the mould above the height of the weir (29) and subsequent dropping of that level to the height of the weir (29). This enables the terminal to be formed at precisely the correct height without the need for any metering of the lead.

Abstract: A method and apparatus for controlling the dispersion of molten metal in a mold cavity is disclosed, the control facilitated by a localized densification of foam in a lost foam casting operation for producing metal castings, wherein the filling of regions of the mold cavity which do not lend themselves to castability is maximized, an amount of backfill and casting defects are minimized, and a flow pattern of molten metal and material properties of the resulting casting are optimized.

Abstract: An apparatus for preventing bulging of both edges of a strip while preventing contamination of a roll surface in a twin roll strip caster including a meniscus shield (5) and a plurality of weirs (12).

Abstract: An apparatus for shelling an investment casting pattern has a tank containing a coating material. There are means for holding the pattern immersed in the coating material. There may be means for vibrating the pattern during immersion of the pattern and a vacuum source coupled to the tank to withdraw air from at least one headspace of the tank.

Abstract: A process and apparatus for thermoplastic casting of a suitable glass forming alloy is provided. The method and apparatus comprising thermoplastically casting the alloy in either a continuous or batch process by maintaining the alloy at a temperature in a thermoplastic zone, which is below a temperature, Tnose, (where, the resistance to crystallization is minimum) and above the glass transition temperature, Tg, during the shaping or moulding step, followed by a quenching step where the item is cooled to the ambient temperature. A product formed according to the thermoplastic casting process is also provided.

Abstract: A method of casting a directionally solidified (DS) or single crystal (SX) article with a casting furnace having a heating chamber (4), a cooling chamber (5), a separating baffle (3) between the both chambers includes a first step in which the shell mould (12) is filled with liquid metal (15), and the liquid metal (15) is directionally solidified by withdrawing the shell mould (12) from the heating to the cooling chamber (4, 5). An inert gas impinges from nozzles (8) arranged below the baffle (3) on the shell mould (12) and in steep transitions in outer surface area of the shell mould (12) the flow of the inert gas (9) is reduced or even stopped and when a protruding geometrical feature has passed the impingement area of the gas jets, the gas flow (9) is restored to a value adjusted to the geometry of the cast part presently passing the impingement area.

Abstract: A mold design is disclosed for precision sand casting of engine cylinder blocks, such as engine cylinder V-blocks, having chills disposed therein, wherein an expansion and contraction caused by changes in temperature during the casting operation are accommodated by the chills.

Abstract: A disintegrative member, such as a salt core, is provided with a vent opening extending through its thickness from an outer surface to an inner surface in order to allow gases to pass radially inwardly through the body of the salt core and away from a region proximate the salt core's outer surface. The escape of these gases through the vent opening decreases the likelihood that porosity will be formed as a result of those gases being trapped in a region proximate the outer surface of the salt core because the molten metal solidifies more slowly in this area because of the thermal insulative qualities of the disintegrative member.

Abstract: A method for preparing engine block cylinder bore liners is disclosed, the method including preconditioning of the cylinder bore liners for use in sand casting of engine cylinder blocks, wherein an efficiency of the preconditioning process is maximized, a metal pour temperature is minimized, and material properties of the casting are optimized.

Abstract: A method and a system are for the control of a gas-containing hidden flow of molten metal in a space defined by a tubular device. From measurements in at least one predetermined layer of the metal flow in the space, an indication is obtained of the appearance of the flow which is compared with stored values. The result of the comparison is used for controlling at least one flow-affecting parameter in such a manner that a desired type of flow is provided at least in the layer.

Abstract: A filter material for molten aluminum, the material subsequently dissolvable in molten aluminum to recover aluminum captured therein.

Abstract: An apparatus 1 for producing a composite material including ceramic hollow particles and one of aluminum and aluminum alloy pressurizes a gas feeding member 20, a molten stock vessel 30, a packing 50, a forming mold 60 and an air-removal ceramic filter 80 by means of an upper pressure die 11 and a lower pressure die 12 and introduces an Ar gas thereby allowing molten aluminum 40 or molten aluminum alloy 40 to infiltrate in gaps between the plural ceramic hollow particles.

Abstract: A mold is provided for enabling casting of single crystal metallic articles including a part-defining cavity, a sorter passage positioned vertically beneath and in fluid communication with the part-defining cavity, and a seed cavity positioned vertically beneath and in fluid communication with the sorter passage. The sorter passage includes a shape suitable for encouraging a single crystal structure in solidifying molten metal. Additionally, a portion of the mold between the sorter passage and the part-defining cavity includes a notch for facilitating breakage of a cast article proximate the notch during thermal stress build-up, so as to prevent mold breakage or the inclusion of part defects.

Abstract: A cooling mechanism for a casting apparatus having a mold that includes sides, a bottom, and a top defining a cavity. The cooling mechanism allows for simultaneous injection of liquid and gas onto a cast ingot therefore providing a lower minimum operation liquid flow rate, while maintaining a fairly constant coolant impingement location on the ingot surface. As a result, heat is extracted from the metal ingot at a much lower rate allowing the ingot to experience superior startup butt curl control, which substantially reduces the number of localized stresses that can lead to cracking of the ingot. Reducing the number of cracks in the ingot substantially reduces the number of wasted ingots, therefore improving efficiency and reducing costs. A method of casting is also disclosed.

Abstract: The invention relates to a device for manufacturing models layer by layer. The inventive device comprises a frame (1), a vertically adjustable and exchangeable workpiece platform (17)m and a device for feeding the material comprising a coating applicator (4). Said coating applicator (4) serves to feed material from a storage container to a process zone above the workpiece platform (17), said workpiece platform (17) being fixed in the device at least during manufacturing of a model. The workpiece platform (17) is introduced on the one side of the device and extracted on the other side of the device.

Abstract: Incorporation of rice hull ash into investment casting shell molds improves the permeability, shell build thickness, and/or shell build uniformity of the molds. A method to make the molds entails mixing refractory filler, rice hull ash, and preferably a fiber to form a dry blend; mixing the dry blend with a binder sol to form a refractory slurry, and employing the refractory slurry to produce an investment casting shell mold.

Abstract: Apparatus for continuous vertical casting of metal strips, comprising: a mould (10) having top and bottom ends an open-ended mould cavity (C), a tundish (11) having a discharge opening (11A) in direct communication with the mould cavity (C) to feed molten metal into a mould entrance opening (E) past an interface between the tundish (11) and the mould (10); a sealing device (14) forming a seal at said tundish-mould interface to prevent molten metal from entering said interface, and a device (12) for supplying molten metal to the tundish (11) and maintaining a level of molten metal therein. The scaling device (14) comprises a pair of flat horizontal surfaces (10A, 11B), one on the mould around the entrance opening (E) and one on the tundish (10) around the discharge opening (11A), and a sealing element (14A) formed of a sheet of graphite and being in constant sealing engagement with both said surfaces (10A, 11B).

Abstract: A DC casting mold for casting molten metal alloy comprising a cooled tubular body that has a thermally insulated insert attached to its top surface. The thermally insulated insert has a bottom portion with a beveled sidewall, which forms an angle with the horizontal melt surface layer of the molten metal and creates an eddy. The eddy causes a substantial number of oxides that are formed during the casting process to remain in the bottom sidewall portion of the thermally insulated insert of the mold, thereby substantially reducing the number of ingot surface imperfections that promote ingot cracking. In addition, the eddy promotes break-up of the oxides into smaller pieces as the oxides flow toward the cooled inner walls of the cooled tubular body, thereby having limited surface area for growth of oxide folds. A method of casting molten metal alloys with improved surface quality is also disclosed.