Abstract: A pouring tube for feeding molten steel into the pouring zone of a continuous casting mold includes a tube portion connected to a pouring container and an end portion provided with a bottom piece. To ensure safe operation of the pouring tube and an improved flow distribution, the bottom piece has in the direction of outlet openings thereof a width which is smaller, between 30% and 80%, than the distance between the walls which form the upper limits of the outlet openings.

Abstract: A paper sleeve and system for application as an insulated riser in a sand mold used to cast metal articles is disclosed. The sleeve, preferably cylindrical, is formed from a plurality of sheets of paper wrapped around one another with, preferably, a space between the edges of each sheet to provide a plurality of spaces or openings extending through the sleeve. Each sheet is treated with a precise amount of fire retardant. The sleeve for a given time period acts as an insulator keeping metal therein liquid until the metal solidifies in the article forming cavity of the sand mold and thereafter decomposes or reduces itself to a harmless carbon ash. The sleeve can function to both feed liquid metal to the article forming cavity in a sand mold and also to supply additional liquid metal to the article cavity upon solidification of the metal therein to eliminate the need for separate risers as now required in conventional foundry practice.

Abstract: A method for producing a reinforced composite material. A molten matrix metal is heated to a temperature substantially greater than the melting point of the matrix metal. The matrix metal is poured into a mold containing a mass of reinforcing material, and an oxide layer formed from said molten matrix metal is ruptured so that the molten matrix metal infiltrates the mass of reinforcing material.

Abstract: An apparatus for casting metal includes an outer housing, a liner disposed within the housing and defining a melt tank therewithin, at least one layer of insulation between the housing and the liner, a heating element, a shot tube in the housing external of the melt tank, and a piston disposed within the shot tube for ejecting molten metal from an outlet thereof. A method of die casting a metal is also disclosed, as well as a die casting system including the described apparatus.

Abstract: The present invention relates to a novel method for forming metal matrix composite bodies and the novel products produced therefrom. A negative shape or cavity, which is complementary to the desired metal matrix composite body to be produced, is first formed. The formed cavity is thereafter filled with a permeable mass of filler material. Molten matrix metal is then induced to spontaneously infiltrate the filled cavity. Particularly, an infiltration enhancer and/or an infiltration enhancer precursor and/or an infiltrating atmosphere are also in communication with the filler material, at least at some point during the process, which permits the matrix metal, when made molten, to spontaneously infiltrate the permeable mass of filler material, which at some point during the processing, may become self-supporting. In a preferred embodiment, cavities can be produced by a process which is similar to the so-called lost-wax process.

Abstract: A two-piece shot sleeve for use with a die casting machine including first and second cylindrical sleeve sections being removably axially secured together, each open at both ends and including an interior passage for the flow of molten metal, the second sleeve section also including a pour hole for receiving molten metal into the interior passage. The invention also relates to a die casting machine including a die, a source of molten liquid for casting, a two-piece shot sleeve including a die end section and a pour end section, a plunger disposed within shot sleeve for forcing molten liquid through the shot sleeve into the die and, a ram for moving plunger axially within shot sleeve, wherein the pour end section of the two-piece shot sleeve is removable from the machine without removing the die end section.

Abstract: Molten metal is die cast directly to and around a surface of a fiber reinforced plastic part in such a way as to actually take advantage of the thermal decomposition of the part resin caused by the hot metal. The molten metal is introduced to the surface and cooled just rapidly enough to allow a controlled, limited resin decomposition to occur at the top surface. Molten metal then flows in and around the exposed fibers, creating a secure interlock.

Abstract: A superior unitary one quarter mile long railroad rail and system and method for manufacturing the same. The method of manufacture is characterized by the use of a continuous rolling process and the in-line controlled cooling of the rail. The long railroad rail is rolled in a single direction with a plurality of in-line rolling stations.

Abstract: A method for impregnating an aluminum product with a hard wear resistant surface area comprises providing a desired pattern of particles thereon, providing a sand core which has an high temperature adhesive layer on at least a portion thereof and transferring the pattern of particles onto the adhesive layer, in such a manner so as to minimize contact with the adhesive. After the adhesive is cured, an aluminum melt is cast around the carbides so as to produce an aluminum product having a wear resistant material surface layer. Preferably, the aluminum alloy contains about 4% by weight of copper and the wear resistant material comprises tungsten carbide containing 12 wt. % Co. In one embodiment, the particles are transferred onto the adhesive layer through the use of an adhesive tape which is used to pick up the pattern of particle and then placed upon the adhesive layer on the core surface.

Abstract: A method for impregnating an iron product with a hard wear-resistant material surface layer comprises providing a pattern of particles onto a high temperature adhesive layer on a sand core and casting of the iron melt around the particles so as to produce an iron product. Preferably, the pattern of particles is produced by providing a mesh plate having a desired pattern of holes and spreading the particles onto the sheet. The pattern of particles is then transferred on to the adhesive layer so as to minimize contact with the adhesive. This can be accomplished, for example, through the use of adhesive tape. Preferably, the iron product of the present invention comprises ductile iron while the wear-resistant material comprises tungsten carbide which can include about 12 wt % Co.

Abstract: The present invention relates to a novel process for forming macrocomposite bodies and the novel bodies formed thereby. Particularly, a suitable matrix metal, typically in a molten state, is in contact with a suitable mass of filler material or preform located adjacent to, or in contact with, at least one second material in the presence of a suitable reactive atmosphere in an impermeable container, at least at some point during the process, which permits a reaction to occur between the reactive atmosphere and the molten matrix metal and/or mass of filler material or preform and/or impermeable container, thereby causing molten matrix metal to infiltrate the mass of filler material or preform due to, at least in part, the creation of a self-generated vacuum. Such self-generated vacuum infiltration occurs without the application of any external pressure or vacuum.

Abstract: A ventilated disk used in automobiles and industrial vehicles includes a pair of mutually opposing disk portions, a plurality of radially extending ribs integrally formed with the disk portions and interposed therebetween, and at least one annular damping member. Formed in each rib is at least one radially extending oblong hole which passes through the rib in the circumferential direction. The oblong holes in the respective ribs form at least one circular array along a circular whose center is the center of the disk. The annular damping member(s) extends/extend through the oblong holes forming the annular array(s) and is in contacting engagement with the outer end portion and side portion of each oblong hole.

Abstract: A method for producing composite materials by forming one material in a die cavity such that another material can be forced into the same die cavity and infiltrate the spaces in the first material. A method for producing a composite comprising the steps of injecting reinforcement material in a binder or suspension into a die cavity; burning off or removing the binder or suspension such that the reinforcement material remains in the die cavity; injecting liquid metal into the same die cavity such that it infiltrates the reinforcement material; solidifying the liquid metal; and removing the metal infiltrated composite material from the die cavity. An apparatus comprised of a die and a die cavity disposed inside the die. The apparatus is also comprised of a first port extending from the die cavity to the surface of the die through which reinforcement material in a binder is injected into a die cavity.

Abstract: A centrifugal vacuum assist ambient air casting apparatus and method to fill a casting flask having a mold with a pour opening in communication with the pour opening of a casting crucible filled with molten metal and ceramics comprising: centrifugally spinning the casting flask and casting crucible with their pour openings aligned such that the resulting centrifugal forces empty the contents of the casting crucible into the casting flask, while simultaneously applying a directional vacuum to the casting flask in alignment with the resultant centrifugal forces to evacuate trapped gases from the mold and assist in drawing in the molten metal and ceramics into the mold.

Abstract: A mold containing a gasifiable or vaporizable disposable pattern 3, embedded in sand 4 without a binding agent, is fed through its base by a pressurized chamber 6 containing liquid cast metal. The pressure in the chamber 6 is regulated as a function of the surface area/volume ratio of the disposable pattern 3 to prevent the emergence of high-gloss carbon.

Abstract: A process and apparatus for feeding molten metal to the ingot mold (2) of an installation for the continuous casting of thin cogs (3). At least one jet (6) coming from a nozzle (8) connected to a distributor (4) feeds an ingot mold (2) in which the level of metal is regulated. The distributor (4) is movable vertically in order to keep the height of the jet (6) constant and horizontally in the direction of the largest dimension of the ingot mold in order to subject the jet (6) to an alternating lateral movement. The nozzle (8) and the casting tube (10) are protected by a liquefied neutral gas circulating between the tube (10) and a sleeve (25) surrounding the tube (10).

Abstract: The present invention relates to the formation of a metal matrix composite body by a spontaneous infiltration technique. Particularly, an infiltration enhancer and/or infiltration enhancer precursor can be positioned at least partially between or at an interface between a matrix metal and a filler material (or preform) which is to be infiltrated by molten matrix metal. Moreover, at least at some point during the process, an infiltrating atmosphere may be in communication with the filler material or preform and/or matrix metal.

Abstract: The present invention provides a mold additive for continuous casting which comprises adjusting an additive for stationary casting containing a flux base and, if necessary, a melting property regulator wherein it contains 4-30 wt % of MgO and 4-30 wt % of ZrO.sub.2 and CaO/SiO.sub.2 is 0.5-1.5.

Abstract: A metal matrix composite is formed by contacting a molten matrix alloy with a permeable mass of filler material or preform in the presence of an infiltrating atmosphere. Under these conditions, the molten matrix alloy will spontaneously infiltrate the permeable mass of filler material or preform under normal atmospheric pressures. Once a desired amount of spontaneous infiltration has been achieved, or during the spontaneous infiltration step, the matrix metal which has infiltrated the permeable mass of filler material or preform is directionally solidified. The directionally solidified metal matrix composite may be heated to a temperature in excess of the liquidus temperature of the matrix metal and quenched. This technique allows the production of spontaneously infiltrated metal matrix composites having improved microstructures and properties.

Abstract: The present invention relates to a novel process for forming net or near net-shape metal matrix composite bodies. Particularly, a molten matrix metal is in contact with a filler material or a preform in the presence of a reactive atmosphere, at least at some point during the process, which permits molten matrix metal to react, at least partially or substantially completely, with the reactive atmosphere, thereby causing molten matrix metal to infiltrate the filler material or preform due to the creation of a self-generated vacuum. Forming a glassy seal on the reaction system, the self-generated vacuum infiltration occurs without the application of any external pressure or vacuum. The molten matrix metal infiltrates the filler material up to at least a portion of a provided barrier means.