Abstract: A method of casting a core includes the steps of preparing a first half of a corebox, preparing a second half of a corebox such that the parting line of a core formed from the first and second coreboxes runs along the vertical axis of the core.

Abstract: A method of casting a core includes the steps of preparing a first half of a corebox, preparing a second half of a corebox such that the parting line of a core formed from the first and second coreboxes runs along the vertical axis of the core.

Abstract: A method of casting a core includes the steps of preparing a first half of a corebox, preparing a second half of a corebox such that the parting line of a core formed from the first and second coreboxes runs along the vertical axis of the core.

Abstract: A method of casting a core includes the steps of preparing a first half of a corebox, preparing a second half of a corebox such that the parting line of a core formed from the first and second coreboxes runs along the vertical axis of the core.

Abstract: A knuckle may include a throat portion having a throat side wall with at least three sections, a first section closest to the knuckle tail, a third section closest to the knuckle pulling face, and a second section between said first and third sections. The wall thickness of said first section may be less than 10% different than the wall thickness of said second section. The throat portion may also include a tail stop side wall with at least three sections, a first section closest to the knuckle tail, a third section closest to the knuckle pulling face, and a second section between said first and third sections. The wall thickness of said first section may be less than 10% different than the wall thickness of said second section.

Abstract: A method of casting a core includes the steps of preparing a first half of a corebox, preparing a second half of a corebox such that the parting line of a core formed from the first and second coreboxes runs along the vertical axis of the core.

Abstract: A method for manufacturing a railcar coupler knuckle includes, before casting, positioning an external chill within a cope mold portion and a drag mold portion offset from and adjacent internal walls of a pulling face and a throat of the cope and drag mold portions, thus producing a casting with reduced micro-shrinkage in at least the throat, a high-stress section of the casting. Use of subsurface chills produces an improved surface with fewer inclusions when compared to an equivalent surface produced in a process without use of a subsurface chill. The external chill may be a cone chill of a larger size to improve cooling and solidification at and below the surface. The external chill may also be a cylindrical and/or oblong chill with a tapered design that may correspond to the internal walls of the cope and drag mold portions between the pulling face and the throat.

Abstract: A method for manufacturing a railcar coupler knuckle includes, before casting, positioning an external chill within a cope mold portion and a drag mold portion offset from and adjacent internal walls of a pulling face and a throat of the cope and drag mold portions, thus producing a casting with reduced micro-shrinkage in at least the throat, a high-stress section of the casting. Use of subsurface chills produces an improved surface with fewer inclusions when compared to an equivalent surface produced in a process without use of a subsurface chill. The external chill may be a cone chill of a larger size to improve cooling and solidification at and below the surface. The external chill may also be a cylindrical and/or oblong chill with a tapered design that may correspond to the internal walls of the cope and drag mold portions between the pulling face and the throat.

Abstract: A method of casting a core includes the steps of preparing a first half of a corebox, preparing a second half of a corebox such that the parting line of a core formed from the first and second coreboxes runs along the vertical axis of the core.

Abstract: A method for manufacturing a railcar coupler knuckle includes, before casting, positioning an external chill within a cope mold portion and a drag mold portion offset from and adjacent internal walls of a pulling face and a throat of the cope and drag mold portions, thus producing a casting with reduced micro-shrinkage in at least the throat, a high-stress section of the casting. Use of subsurface chills produces an improved surface with fewer inclusions when compared to an equivalent surface produced in a process without use of a subsurface chill. The external chill may be a cone chill of a larger size to improve cooling and solidification at and below the surface. The external chill may also be a cylindrical and/or oblong chill with a tapered design that may correspond to the internal walls of the cope and drag mold portions between the pulling face and the throat.

Abstract: A knuckle may include a throat portion having a throat side wall with at least three sections, a first section closest to the knuckle tail, a third section closest to the knuckle pulling face, and a second section between said first and third sections. The wall thickness of said first section may be less than 10% different than the wall thickness of said second section. The throat portion may also include a tail stop side wall with at least three sections, a first section closest to the knuckle tail, a third section closest to the knuckle pulling face, and a second section between said first and third sections. The wall thickness of said first section may be less than 10% different than the wall thickness of said second section.

Abstract: A method of manufacturing a side frame of a rail car, where the side frame includes a pair of pedestals for mounting wheel sets, includes providing a side frame pattern for forming a drag portion and a cope portion of a mold. Cores that define an interior region of a cast side frame are also provided. The side frame pattern and the cores are configured to constrain a spacing between the pair of pedestals to within about ±0.038 inches.

Abstract: A method of casting a core includes the steps of preparing a first half of a corebox, preparing a second half of a corebox such that the parting line of a core formed from the first and second coreboxes runs along the vertical axis of the core.

Abstract: A knuckle may include a throat portion having a throat side wall with at least three sections, a first section closest to the knuckle tail, a third section closest to the knuckle pulling face, and a second section between said first and third sections. The wall thickness of said first section may be less than 10% different than the wall thickness of said second section. The throat portion may also include a tail stop side wall with at least three sections, a first section closest to the knuckle tail, a third section closest to the knuckle pulling face, and a second section between said first and third sections. The wall thickness of said first section may be less than 10% different than the wall thickness of said second section.

Abstract: A method of casting a core includes the steps of preparing a first half of a corebox, preparing a second half of a corebox such that the parting line of a core formed from the first and second coreboxes runs along the vertical axis of the core.

Abstract: A casting mold with rigging for casting a railcar coupler, which includes a shank portion and a head portion, includes cope and drag portions that define an external shape for each of at least two couplers. The couplers are nested together and oriented in opposite directions to one another along respective longitudinal axes. A down sprue is centered between the first and second couplers and is configured to direct molten material to a gating system positioned between the at least two couples.

Abstract: A knuckle may include a throat portion having a throat side wall with at least three sections, a first section closest to the knuckle tail, a third section closest to the knuckle pulling face, and a second section between said first and third sections. The wall thickness of said first section may be less than 10% different than the wall thickness of said second section. The throat portion may also include a tail stop side wall with at least three sections, a first section closest to the knuckle tail, a third section closest to the knuckle pulling face, and a second section between said first and third sections. The wall thickness of said first section may be less than 10% different than the wall thickness of said second section.

Abstract: A casting apparatus for casting a railcar coupler, which includes a shank portion and a head portion, includes cope and drag portions that define an external shape of the coupler. The casting apparatus also includes one or more cores that define an interior of the shank portion and a separate head core with an exterior that defines an interior of the head portion that includes lock chamber, guard arm side portion, and knuckle side portions of the head. The head core is a single piece with a hollow center section that defines a front face gating system that includes at least one in-gate configured to direct molten material to top and bottom regions of the head to define the lock chamber, guard arm side portion, and knuckle side of the head.

Abstract: A core assembly for creating interior spaces in a railcar coupler knuckle is designed to be set in a cavity with cope and drag sections. The cavity is shaped to form a railcar coupler knuckle and includes a first wall that forms the substantially vertical outside wall of the tail of the knuckle. The core includes a kidney section with a rear core support section that extends at least 0.5? outside the first wall of the cavity when the core is set in the drag.

Abstract: A method of casting a core includes the steps of preparing a first half of a corebox, preparing a second half of a corebox such that the parting line of a core formed from the first and second coreboxes runs along the vertical axis of the core.