Abstract: Apparatus and method for DS casting using one or more thermal baffle members positionable at a lower open end of a directional solidification casting furnace by movement of a ram on which a mold to be cast is moved relative to the casting furnace. A unique thermal baffle member can be used for each particular series or run of molds to be cast.

Abstract: Method as well as apparatus for DS casting by withdrawing a melt-filled mold from an end of a casting furnace, spraying a liquid cooling medium to impinge on exterior surfaces of the mold as the mold is withdrawn, and collecting the cooling medium after it impinges on the exterior mold surfaces.

Abstract: Molten metallic material is cast into a mold that is made with a barrier to reduce gas permeability through a mold wall that forms on its innermost side a mold surface for contacting the molten metallic material. The molten metallic material is gravity cast into the mold residing in a furnace in a casting chamber under a first pressure, such as subambient pressure. Then, a gaseous pressure is provided in the casting chamber higher than the first pressure rapidly enough to reduce or eliminate the presence of localized voids in the casting solidified in the mold.

Abstract: Molten metallic material is cast into a mold that is made with a barrier to reduce gas permeability through a mold wall that forms on its innermost side a mold surface for contacting the molten metallic material. The molten metallic material is gravity cast into the mold residing in a furnace in a casting chamber under a first pressure, such as subambient pressure. Then, a gaseous pressure is provided in the casting chamber higher than the first pressure rapidly enough to reduce or eliminate the presence of localized voids in the casting solidified in the mold.

Abstract: Method as well as apparatus for DS casting using a multi-stage thermal baffle disposed proximate a lower end of a DS casting furnace. The thermal baffle comprises a fixed primary baffle disposed at the lower end of the casting furnace and a secondary baffle initially releasably disposed adjacent and below the primary baffle prior to withdrawal of the melt-filled mold from the casting furnace. The primary baffle includes a primary aperture oriented perpendicular to the mold withdrawal direction and having a cross-sectional configuration tailored to accommodate a relatively large exterior region or profile of the melt-filled mold, such as a relatively wide platform region of a mold for making a turbine blade or vane.

Abstract: Method as well as apparatus for DS casting using a multi-stage thermal baffle disposed proximate a lower end of a DS casting furnace. The thermal baffle comprises a fixed primary baffle disposed at the lower end of the casting furnace and a secondary baffle initially releasably disposed adjacent and below the primary baffle prior to withdrawal of the melt-filled mold from the casting furnace. The primary baffle includes a primary aperture oriented perpendicular to the mold withdrawal direction and having a cross-sectional configuration tailored to accommodate a relatively large exterior region or profile of the melt-filled mold, such as a relatively wide platform region of a mold for making a turbine blade or vane.

Abstract: Method as well as apparatus for DS casting using a multi-stage thermal baffle disposed proximate a lower end of a DS casting furnace. The thermal baffle comprises a fixed primary baffle disposed at the lower end of the casting furnace and a secondary baffle initially releasably disposed adjacent and below the primary baffle prior to withdrawal of the melt-filled mold from the casting furnace. The primary baffle includes a primary aperture oriented perpendicular to the mold withdrawal direction and having a cross-sectional configuration tailored to accommodate a relatively large exterior region or profile of the melt-filled mold, such as a relatively wide platform region of a mold for making a turbine blade or vane.

Abstract: Method and apparatus for directional solidification of molten metal using a general horizontally oriented mold initially positioned in a casting furnace. The mold is filled with molten metal through a mold pour cup located on an upper region of the mold and a pour cup runner that enters the mold at location proximate a grain selection passage. The melt filled mold initially is withdrawn from the casting furnace to solidify the molten metal at the location where the pour cup runner enters the mold. The melt filled mold then is withdrawn while the mold is rotated about its horizontal axis to reduce segregation of alloying elements in the solidifying molten metal. Initial solidification of molten metal at the entry of the pour cup runner to the mold prevents molten metal from flowing out of the mold through the pour cup when the mold is subsequently rotated.

Abstract: Method and apparatus for directional solidification of molten metal employs a generally horizontally oriented mold initially positioned in a casting furnace. The mold residing on a chill is filled with molten metal through a mold pour cup located on an upper region of the mold. The mold is withdrawn from the casting furnace to effect directional solidification. As the molten metal filled mold is withdrawn, the mold is oscillated about a general horizontal axis within an angular range of up to about 180 degrees. Such limited angle oscillation during mold withdrawal reduces segregation of alloying elements in the solidifying molten metal and prevents molten metal from leaving the mold through the pour cup.

Abstract: A method of forming a fine grained equiaxed casting by melting metal and removing most of the superheat of the molten metal. The molten metal is placed in a mold and optionally subjected to turbulence whereupon it solidifies to form the casting of the desired microstructure.

Abstract: A high temperature alloy displaying excellent elevated temperature properties as well as low strategic metals content. Based on the iron/aluminum system, the alloy contains about 10 to 19% aluminum, 2 to 8% titanium, from about 0.5 to 10% molybdenium, from 0.1 to 1% hafnium and the balance substantially iron.