Abstract: A casting system and process employs sealed lightweight mold segments that are assembled into a fixture that serves as a mold transportation device that is delivered via a mold line to a production line roll-over system which performs as a metal pouring station. This system may be employed in sand, semi-permanent and permanent casting environments. The fixture is pressurized with He, inverted by the roll-over system, then connected to a low-pressure furnace where metal pouring begins while maintaining pressurized He in the mold cavity. A counter-gravity delivery system allows the low-pressure furnace to deliver molten lightweight material that is free from oxides and dissolved hydrogen gas into the mold cavity.

Abstract: A foundry casting system and process employs an inert gas delivery and recovery system for casting parts which results in cast parts having improved metalurgical characteristics. The system may be employed in sand, die casting, semi-permanent and permanent casting environments. Pressurized inert gas may be diffused into the mold before, during and after the metal pouring step. The resulting casting is free from oxides and dissolved hydrogen gas as they are removed from the mold cavity. This results in higher quality castings as well as increased production output due to faster cooling cycles.

Abstract: A foundry casting system and process employs an inert gas delivery and recovery system for casting parts which results in cast parts having improved metalurgical characteristics. The system may be employed in sand, die casting, semi-permanent and permanent casting environments. Pressurized inert gas may be diffused into the mold before, during and after the metal pouring step. The resulting casting is free from oxides and dissolved hydrogen gas as they are removed from the mold cavity. This results in higher quality castings as well as increased production output due to faster cooling cycles.

Abstract: A casting system and process employs sealed lightweight mold segments that are assembled into a fixture that serves as a mold transportation device that is delivered via a mold line to a production line roll-over system which performs as a metal pouring station. This system may be employed in sand, semi-permanent and permanent casting environments. The fixture is pressurized with He, inverted by the roll-over system, then connected to a low-pressure furnace where metal pouring begins while maintaining pressurized He in the mold cavity. A counter-gravity delivery system allows the low-pressure furnace to deliver molten lightweight material that is free from oxides and dissolved hydrogen gas into the mold cavity.

Abstract: A foundry casting system and process employs an inert gas delivery and recovery system for casting parts which results in cast parts having improved metalurgical characteristics. The system may be employed in sand, die casting, semi-permanent and permanent casting environments. Pressurized inert gas may be diffused into the mold before, during and after the metal pouring step. The resulting casting is free from oxides and dissolved hydrogen gas as they are removed from the mold cavity. This results in higher quality castings as well as increased production output due to faster cooling cycles.

Abstract: Disclosed is a metal casting system, an engineered mold for use therewith, a process for utilizing the system and mold, and articles having a clean, oxide-free sand casting of molten metals that have been produced under an inert environment. This is especially advantageous for making automotive and airplane parts from the manufacture of lightweight metals, and more especially for the production of magnesium parts in order to reduce weight while maintaining properties found in other lightweight metals. Currently, sand cast articles are being used for automotive, aerospace and semiconductor parts and other industrial applications.

Abstract: Disclosed is a metal casting system, an engineered mold for use therewith, a process for utilizing the system and mold, and articles having a clean, oxide-free sand casting of molten metals that have been produced under an inert environment. This is especially advantageous for making automotive and airplane parts from the manufacture of lightweight metals, and more especially for the production of magnesium parts in order to reduce weight while maintaining properties found in other lightweight metals. Currently, sand cast articles are being used for automotive, aerospace and semiconductor parts and other industrial applications.

Abstract: A method of treating molten metals is disclosed which employs a solid sheathless flexible strand containing particles of the treating agent uniformly suspended in a binder matrix, the latter being consumable or vaporizable upon contact with molten metal. Positive and predetermined solution conditions of the treating agent are assured by regulating the molten metal flow velocity to be at or above a predetermined minimum and the strand injection rate to be within defined limits.

Abstract: A pattern destructible on contact with a molten metal charge is given a composite coating consisting of a (1) highly tacky viscous adhesive substantially devoid of solids and having a low gas content, (2) a collection of ultra-fine refractory paticles (carbon facing sand) aligned on the surface of said adhesive. The adhesive volatilizes on contact with the casting charge while the refractory particles remain unaffected. An ultra-smooth cast surface is produced without macro crevices inherent in the surface of a destructible pattern and the mold sand is reusable without contamination by a high portion of burned sand.

Abstract: A method of treating molten metals is disclosed which employs a solid sheathless flexible strand containing particles of the treating agent uniformly suspended in a binder matrix, the latter being consumable or vaporizable upon contact with molten metal. Positive and predetermined solution conditions of the treating agent are assured by regulating the molten metal flow velocity to be at or above a predetermined minimum and the strand injection rate to be within defined limits.

Abstract: An improved catalyst is disclosed for making spheroidal graphite cast iron, the catalyst being in the form of a solid impervious and brittle block but severed from a sheet stock having a predetermined grid pattern of perforations or notches along at least one surface of said sheet stock. The block is substantially devoid of segregation and oxide interiorally thereof; the thickness of said block is increased over that capable of being produced by the prior art in the as-cast condition and yet devoid of segregation. The method of making such block comprises casting the molten catalyst into shallow closed pans, the cover for said pans carrying a pattern of ribs or projections, the cover and pan cooperating to define a selected configuration for an as-cast sheet stock. The resulting cast product can be manually or automatically broken along any desired module, defined by said grid pattern, to suit a variety of in plant casting applications particularly utilizing in-the-mold nodularizing treatment.

Abstract: A method and apparatus is disclosed for conditioning a charge of molten cast iron, which would normally solidify with a flake graphite structure, to produce partial or total spheroidal graphite cast iron. In addition, the method and apparatus can be used to further condition a partially conditioned cast iron to yield a partial or fully spheroidal graphite cast iron. A recess is provided in the metal flow system (within or without the mold system) leading to the casting cavity or cavities. The recess has a shape and cross-section (taken in directions normal to the direction of flow of the molten charge) such that the spheroidizing agent dissolves uniformly when the molten iron flows over it to achieve unprecedented homogeneity. A dense solid unitary block of spheroidizing or nodularizing agent, substantially devoid of MgO interiorly thereof, is typically snugly fitted in said recess and mates with the side walls and bottom of said recess.

Abstract: A method of making aluminum castings having a self-fused high silicon content in the interior matrix near and at the surface. A sand core is coated with a tacky, low-ash, low-volatile adhesive along a predetermined zone. Silicon dust particles are deposited on said adhesive in bonded relation. Molten aluminum is cast into a mold cavity containing the coated core. After mold stripping, the silicon particles are exposed as metallurgically bonded to the aluminum but along an ultra-thin depth. At least some of the exposed silicon particles are machined to expose a planar facet and thereby increase the projected exposure of the silicon particles along the machined plane. The resulting product has a reduced shrinkage characteristic (typical of aluminum alloys having a high proportional precipitated silicon).

Abstract: A method of making aluminum castings having a self-fused high silicon content in the interior matrix near and at the surface. A sand core is coated with a tacky, low-ash, low-volatile adhesive along a predetermined zone. Silicon dust particles are deposited on said adhesive in bonded relation. Molten aluminum is cast into a mold cavity containing the coated core. After mold stripping, the silicon particles are exposed as metallurgically bonded to the aluminum but along an ultra-thin depth. At least some of the exposed silicon particles are machined to expose a planar facet and thereby increase the projected exposure of the silicon particles along the machined plane. The resulting product has a reduced shrinkage characteristic (typical of aluminum alloys having a high proportional precipitated silicon).

Abstract: A pattern destructible on contact with a molten metal charge is given a composite coating consisting of a highly tacky viscous adhesive substantially devoid of solids and single particle thickness layer collection of ultra-fine refractory particles (carbon facing sand) aligned on the surface of said adhesive. The adhesive volatilizes on contact with the casting charge while the refractory particles remain unaffected. An ultra-smooth cast surface is produced without macro crevices inherent in the surface of a destructible pattern and the mold sand is reusable without contamination by a high portion of burned sand.

Abstract: A method of making a more economical and reliable treating agent for use in late metal treatment when pouring metal castings. The treating agent is defined as an essentially homogeneous solid cast block preferably containing alloying ingredients to nodulize or inoculant ferrous metal. Each block is designed to present a generally uniform reaction surface to molten metal to be treated. This is obtained by casting the block to a shape which snugly fits a prepared basin in the mold gating system over which the molten metal to be treated must flow, or to cast the block in an annular configuration through which the molten metal must flow. The latter block has contoured inner surfaces which maintain a generally constant reactive surface as the block is consumed. These blocks are preferably prepared by simultaneously casting a large number in closely nested relation.