Abstract: A method for manufacturing an alloy component includes forming a mold including a first mold portion and a second mold portion defining a mold cavity therebetween. At least one of the first and second mold portions comprise one or more inserts disposed through an outside surface of a respective mold portion and extending through the respective mold portion proximate to the mold cavity. The method can include delivering a molten alloy into the mold cavity and supporting by the one or more inserts, the molten metal as the molten metal cools to form a part. The one or more inserts can comprise a plurality of hollow tubes extending therethrough, and can enable cooling and/or heating of the molten alloy and/or alloy part through the plurality of hollow tubes.

Abstract: A device that may be a valve or a pinch valve is disclosed. The device includes at least the following components: (1) a flexible sleeve and (2) two end connection ports that are located on opposite ends of the flexible sleeve. The device may also include one or more of the following: an actuator, a body or housing, and a heating element. The flexible sleeve is capable of having the high-temperature material flowed therein and being in direct contact with the flexible sleeve. The high-temperature material is a material at a temperature above 200° C. For example, the high-temperature material may be a molten material in a casting process. A method of using the device is also disclosed. The method involves, at least, the following steps: (1) providing a flexible sleeve, and (2) flowing a high-temperature material into the flexible sleeve. The steps may be part of a casting process involving molten material, such as molten metal or molten metal alloy.

Abstract: A method for manufacturing an alloy component includes forming a mold including a first mold portion and a second mold portion defining a mold cavity therebetween. At least one of the first and second mold portions comprise one or more inserts disposed through an outside surface of a respective mold portion and extending through the respective mold portion proximate to the mold cavity. The method can include delivering a molten alloy into the mold cavity and supporting by the one or more inserts, the molten metal as the molten metal cools to form a part. The one or more inserts can comprise a plurality of hollow tubes extending therethrough, and can enable cooling and/or heating of the molten alloy and/or alloy part through the plurality of hollow tubes.

Abstract: A configurable end-effector is provided for a robotic system used in a casting process. The end-effector can have one or more ablate and/or cooling modules that can apply an ablating material and/or cooling fluid to a mold for the solidification or the solid to solid transformation of the metal component of the part to be cast or formed in the mold or tooling. The end-effector may incorporate one or more air push or vacuum modules that can be used to remove or move the ablate material phase state change and/or the cooling fluid after the ablate material and/or cooling fluid absorbs heat from the part. The end-effector can include one or more energy modules that can be used to introduce heat to the mold and/or tooling and the formed component part so that additional processes can be performed on the component part.

Abstract: A process for the manufacture of metal products includes the steps of providing a mold including a first portion made of an aggregate and a binder, delivering a molten metal into the mold, removing a first portion of the mold with a fluid and solidifying at least one targeted portion of the molten metal which will form the metal product with the fluid. A flow of fluid to the mold is stopped for a period of time. Subsequently, a remaining portion of the molten metal is solidified to form the metal product. The at least one targeted portion of the metal product has better mechanical properties than does a remaining portion of the metal product. A unitary, one-piece aluminum alloy component with differing mechanical properties is also disclosed.

Abstract: A process for the manufacture of metal products includes the steps of providing a mold including a first portion made of an aggregate and a binder, delivering a molten metal into the mold, removing a first portion of the mold with a fluid and solidifying at least one targeted portion of the molten metal which will form the metal product with the fluid. A flow of fluid to the mold is stopped for a period of time. Subsequently, a remaining portion of the molten metal is solidified to form the metal product. The at least one targeted portion of the metal product has better mechanical properties than does a remaining portion of the metal product. A unitary, one-piece aluminum alloy component with differing mechanical properties is also disclosed.

Abstract: A process for the manufacture of metal products includes the steps of providing a mold including a first portion made of an aggregate and a binder, delivering a molten metal into the mold, removing a first portion of the mold with a fluid and solidifying at least one targeted portion of the molten metal which will form the metal product with the fluid. A flow of fluid to the mold is stopped for a period of time. Subsequently, a remaining portion of the molten metal is solidified to form the metal product. The at least one targeted portion of the metal product has better mechanical properties than does a remaining portion of the metal product. A unitary, one-piece aluminum alloy component with differing mechanical properties is also disclosed.

Abstract: A process for the manufacture of metal products includes the steps of providing a mold including a first portion made of an aggregate and a binder, delivering a molten metal into the mold, removing a first portion of the mold with a fluid and solidifying at least one targeted portion of the molten metal which will form the metal product with the fluid. A flow of fluid to the mold is stopped for a period of time. Subsequently, a remaining portion of the molten metal is solidified to form the metal product. The at least one targeted portion of the metal product has better mechanical properties than does a remaining portion of the metal product. A unitary, one-piece aluminum alloy component with differing mechanical properties is also disclosed.

Abstract: A method forms a die-cast metal part having a globular microstructure. The method includes the steps of introducing a metal charge into a chamber in a molten state above the liquidus temperature, and holding the metal charge in the chamber without stirring or agitation until it attains a solid fraction state with a non-homogenous, substantially dendritic microstructure. The metal charge is forced from the chamber through an orifice such that passage through the orifice imparts sheer that breaks the substantially dendritic microstructure to a substantially globular non-dendritic microstructure. The metal charge with the substantially globular non-dendritic microstructure is forced into a cavity having the shape of the die-cast part.

Abstract: A method and apparatus for the lost pattern casting of metals is disclosed. In the method, a pattern is formed from a material and a mold is formed around at least a portion of the pattern. The mold includes a particulate material and a binder. The pattern is removed from the mold and molten metal is delivered into the mold. The mold is contacted with the solvent and the molten metal is cooled such that it at least partially solidifies to form a casting. The step of cooling includes contacting a shell of solidifying metal around the molten metal with the solvent. An apparatus is also disclosed.