Abstract: Method and apparatus for making a ceramic core or fugitive pattern for use in investment casting wherein a fluid ceramic core or pattern material is introduced into a molding cavity defined by cooperating dies, and at least a region of one or both of the dies is heated during filling of the molding cavity with the material and then cooled to a lower ejection temperature before removal of a ceramic core or pattern from the molding cavity.

Abstract: A method of purifying molten metal that reduces the amount of contaminants therein by maintaining the molten metal in a quiescent state allowing buoyant impurities in the metal to float to the top. The top of the molten metal is cooled solidifying the top portion and entrapping the impurities in the solid layer. The molten metal is then cast from beneath the solid portion.

Abstract: Ceramic porous bodies, including ceramic foam filters and smooth-faced ceramic objects, e.g., ceramic foam bricks, ceramic foam melting crucibles, and ceramic foam cores, made in accordance with the present invention are suitable for use with molten metal in general and molten superalloys in particular. The invention also provides a tundish for use with ceramic foam filters to filter metal en route from a metal furnace to a casting mold, and a melting device for use in casting metal which employs a ceramic foam filter as a bottom pour valve for a melting crucible such that the ceramic foam filter valve regulates the flow of molten metal therethrough in order to permit an entire ingot of metal to melt in the melting crucible before any metal begins to pour from the melting device into a casting mold.

Abstract: Ceramic porous bodies, including ceramic foam filters and smooth-faced ceramic objects, e.g., ceramic foam bricks, ceramic foam melting crucibles, and ceramic foam cores, made in accordance with the present invention are suitable for use with molten metal in general and molten superalloys in particular. The invention also provides a tundish for use with ceramic foam filters to filter metal en route from a metal furnace to a casting mold, and a melting device for use in casting metal which employs a ceramic foam filter as a bottom pour valve for a melting crucible such that the ceramic foam filter valve regulates the flow of molten metal therethrough in order to permit an entire ingot of metal to melt in the melting crucible before any metal begins to pour from the melting device into a casting mold.

Abstract: Melting furnace constructions for the melting of ingots, the constructions including crucibles and insulating means for the crucibles. The insulating means serve to separate the charge from the heating means for the construction. The ingots employed are maintained out of contact with the crucible side walls and the crucibles define bottom surfaces which include means for maintaining substantial portions of the ingot bottoms out of contact with the crucible bottom. This arrangement minimizes heat exchange between the charge and the crucible to minimize thermal shock. The crucible is also preferably provided with a capsule of ceramic material cast around the crucible. The capsule and crucible combination is inserted within a liner with the adjacent capsule and liner surfaces substantially conforming whereby ideal support and strength for the combination is accomplished.

Abstract: An apparatus for producing directionally solidified castings wherein a mold having an open bottom is supported on a chill plate with metal poured into the mold initially solidifying adjacent the chill plate and thereafter progressively solidifying away from the chill plate. The chill plate is provided with a plug member, and the metal being cast initially solidifies around this plug member whereby the metal is securely held in intimate contact with the plug member and adjacent chill plate surfaces so that the withdrawal of heat from the casting through the chill plate is greatly facilitated.

Abstract: This invention is addressed to cores for use in the casting of high melting point metals wherein the core is formed of a refractory material, a silicone resin and a catalyst in the form of an anhydride of an organic carboxylic acid.