Abstract: A shaping tool includes a cooling system having one or more cooling passages configured for enhanced cooling. The cooling passages provide latent heat cooling of a heated material that is in contact with a shaping surface of the tool. Cooling fluid flows along the cooling passages in a two-phase flow regime in which a portion of the cooling fluid is liquid and a portion of the cooling fluid is vapor. A two-phase portion of the cooling passage can be shaped to follow a three-dimensional contour of the shaping surface. Opposing walls of the cooling passage can be provided by passage surfaces of separately formed pieces of the tool. The latent heat cooling provided by suitably configured cooling channels extracts more heat from the material being shaped in the tool than traditional cooling systems.

Abstract: A casting apparatus for forming a cylinder head. The apparatus is configured to inhibit gate stick by promoting top-down directional solidification of molten metal in the mold cavity by any one or more of specific placement of gate pins in relation to apertures used to deliver molten metal to the mold cavity, circulating a cooling medium through the gate pins in a parallel fashion, configuring the gates so that a volume on the lower side of the gate is larger than a volume on the upper side of the gate, and insulating the inside surfaces of feeder lids and feeder bowls.

Abstract: In accordance with an exemplary embodiment, a method for manufacturing a tool comprises applying at least one ferro-magnetic material to at least a portion of a tool face of a different material. The method produces a tool face with varying magnetic properties facilitating substantially uniform induction heating of the tool face.

Abstract: A method of making an aluminum piston is described. In one embodiment, the method includes placing a oil gallery core in a mold, the oil gallery core comprising a metal tube connected to a hollow inlet tube and a hollow outlet tube; introducing liquid aluminum into the mold around the oil gallery core; and allowing the liquid aluminum to solidify, the oil gallery core forming a channel in the piston. Aluminum pistons are also described.

Abstract: An annular clean metal casting mold has a mold body which includes a cold bottom mold plate and a peripheral cold mold plate in connection with the cold bottom mold plate. An annular hot preservation layer is disposed inside the peripheral cold mold plate. A cyclic clean crystalline region is formed between the peripheral cold mold plate and the annular hot preservation layer. A sacrificial crystalline region is formed inside the cyclic hot preservation layer. As the outer race of the annular clean crystallization zone contacts large area of the peripheral low cold mold plate, releasing heat rapidly, while the inner race contacts the annular hot preservation layer 3, heat dissipation is extremely slow, naturally result in forming orientational crystallization.

Abstract: A system and method for directionally casting an elongated device are provided. The method includes orienting a mold within a furnace such that a first portion of the mold points downward. The first portion of the mold defines a space within the mold used to form a first end of the device. The first end of the device, when formed, has a greater mass than a second end of the device. The method also includes filling the mold with molten metal and lowering the mold out of the furnace into a liquid metal bath to immerse the first portion of the mold in the liquid metal bath. The method includes concurrently lowering the mold and the liquid metal bath to cool the molten metal.

Abstract: A system and method of making a part. The part may cast in a die. A gripper assembly may be provided that has a gripper and a spray nozzle that provides a fluid. The part may be quenched with a fluid when the part is in the die.

Abstract: An aluminum alloy for a vehicle has the composition including, by weight %, 0.5% or less of Fe, 0.2% or less of Mn, Si, and Cu with the balance being Al and unavoidable impurities, wherein dendrite arm spacing is 45 ?m or less, and a size of an intermetallic compound is 150 ?m or less.

Abstract: The present invention relates to the field of casting blank manufacturing, in particular to a method for enhancing the self-feeding ability of a heavy section casting blank, which can solve the problems of poor centre quality, surface crack and high rejection rate of the heavy section casting blanks in the prior art.

Abstract: A method of casting an alloy is provided, comprising the steps of pouring molten alloy into a mould (18), moving the mould (18) to a first position inside a chamber (12), the chamber (12) including a volume of quenchant (16), increasing the pressure within the chamber (12), and moving the mould (18) to a second position in which at least a portion of the mould (18) is submersed in the quenchant (16), so as to reduce the temperature of the mould (18).

Abstract: A method of providing a mould with a conformal cooling passage includes rough machining a mould cavity generally corresponding to a moulded part shape using CAD data. Conformal cooling slots are cut in the mould cavity using the CAD data. The conformal cooling slots are welded shut using the CAD data to provide conformal cooling passages. A class A surface is machined over the conformal cooling passage and corresponds to a finished mould part shape using the CAD data.

Abstract: Methods for casting a metallic material to form a component are described. The component can be a superalloy-containing turbine part, for example. The general method includes the step of pouring the metallic material, in molten form, into an investment mold; and then rapidly immersing the entire investment mold into a bath that contains a low-melting liquid coolant metal, so as to achieve substantially uniform, multi-directional heat transfer out of the molten material. The molten material that solidifies to form the component is characterized by a fine-grained, equiaxed grain structure. Related embodiments include the use of two ingots that constitute the superalloy material. One ingot includes the oxygen-reactive elements, and is prepared by a vacuum-melting technique. The other ingot includes the remainder of the elements, and can be prepared by a number of techniques, such as air-melting processes.

Abstract: A system and method for directionally casting an elongated device are provided. The method includes orienting a mold within a furnace such that a first portion of the mold points downward. The first portion of the mold defines a space within the mold used to form a first end of the device. The first end of the device, when formed, has a greater mass than a second end of the device. The method also includes filling the mold with molten metal and lowering the mold out of the furnace into a liquid metal bath to immerse the first portion of the mold in the liquid metal bath. The method includes concurrently lowering the mold and the liquid metal bath to cool the molten metal.

Abstract: At the operation of a suction pump, a negative pressure is generated in a supply-side pipe line, a cooling passageway of a mold, and a return-side pipe line. Cooling water stored in a water tank is sucked by the negative pressure, flows from a first feed-water inlet to the supply-side pipe line, flows through the supply-side pipe line, and enters the cooling passageway of the mold. After the cooling water cools down the mold while flowing through the cooling passageway of the mold, it flows out to the return-side pipe line. Additionally, at the operation of the suction pump, a negative pressure is also generated in a bypass pipe line. The cooling water stored in the water tank is sucked by the negative pressure, flows from a second feed-water port to the bypass pipe line, and enters the return-side pipe line via the bypass pipe line.

Abstract: The invention provides a method of reducing butt curl during DC casting of a metal ingot. The ingot is cast in at least two stages, including an initial casting stage and then a steady-state casting stage carried out at higher casting speed. The emerging ingot is cooled by directing a liquid coolant onto its outer surface. During the first casting stage, the liquid coolant is directed in the form of at least two streams, including a constant first stream in the form of a series of first jets, and an intermittent second stream in the form of a series of second jets. The first and second jets impact the outer surface at locations spaced from each other peripherally and/or longitudinally of the ingot. Both the first and second streams experience film boiling when they contact the ingot. The invention includes apparatus for the method.

Abstract: A cooling chamber design that increases the heat transfer over conventional designs during the casting process of an aluminum cylinder head.

Abstract: An investment casting process is provided in which a molten aluminum metal is cast into a refractory mold and thereafter cooled to solidify the metal in the mold. The improvement includes the step of cooling the mold and solidifying the metal therein which is carried out by placing the mold in a chamber adapted to retain a liquid. The mold is mounted in a stationary condition in the chamber. A coolant liquid is introduced into the chamber to immerse the mold in the liquid while maintaining the mold in a stationary condition.

Abstract: A method of casting metal articles includes providing a plurality of interconnected support sections. Article mold sections are positioned on the support sections. After article mold cavities, have been filled with a molten metal which is at a first temperature, the support sections and a body of a second molten metal are moved relative to each other while the body of a second molten metal is at a temperature which is less than the first temperature. Space extending between side surfaces of the support sections and between side portions of the article mold sections is filled with the second molten metal during movement between the support sections and the body of a second molten metal. A layer of insulating material may be provided above the body of a second molten metal. A baffle may be provided between a container holding the body of a second molten metal and a furnace assembly.

Abstract: A cooling chamber design that increases the heat transfer over conventional designs during the casting process of an aluminum cylinder head.

Abstract: Method and apparatus for improving the quality and mechanical properties of an aluminum alloy engine cylinder block or other large or complex castings by providing sand molds bound with a soluble binder only at locations on said casting from which rapid cooling for directional solidification and/or improved localized mechanical properties are desired with said molds being otherwise bound at the remaining locations only with a more typical insoluble binder.

Abstract: A plurality of molds are disposed on a rotatable base. The base is rotated to move each of the molds in turn through a pouring station to an article removing station and back to the pouring station. A molten nickel chrome super alloy is poured into each of the molds in turn at the pouring station. The molds are cooled by a flow of cooling fluid. The nickel chrome super alloy articles are removed from the molds at the article removal station. The base may be continuously or intermittently rotated relative to the pouring station. Molten metal may be continuously or intermittently poured at the pouring station.

Abstract: An improved apparatus for direct chill casting of metals includes a mold, a bottom block assembly and a coolant. The mold is configured to surround a molten metal with a mold wall and the mold wall has an outer surface and an inner surface being in contact with the molten metal. The bottom block assembly is arranged at the bottom of the mold and includes a direct chill casting block configured to move away from the mold as the casting forms a solidifying shell of the molten metal. The coolant surrounds the outer surface of the mold wall and is arranged to remove heat away from the molten metal via the inner surface of the mold wall. The outer surface of the mold wall has a circumferential groove filled with a brazing alloy.

Abstract: A process is provided for manufacturing aluminum vehicle wheels by a casting process that is followed by processing including flow forming and heat treatment steps while one or more risers remain on the cast wheel blank. The process can include directing cooling fluid onto an exposed surface of the casting mold to enhance wheel strength. One-by-one transfer of wheel blanks can be practiced to avoid negative aspects of batch processing.

Abstract: Casting molds suitable for directional solidification processes using a liquid cooling bath include a graded facecoat structure on a mold body. The graded facecoat structure includes an innermost layer and a delamination layer, wherein the delamination layer fractures upon cooling of the molten metal so as to separate the mold body from the innermost layer, which remains in contact with or in close proximity to the metal being cast. Also disclosed are directional solidification processes.

Abstract: A sand based mold and method for casting a device having a cavity. The sand based mold includes a core part including grains of sand bonded with a resin, where a shape of the core part fits a shape of the cavity of the device, and a first pipe embedded into the core part and configured to allow a compressed fluid to flow through the first pipe during a solidification process of the device, the first pipe having an inlet and an outlet that exit the mold.

Abstract: The invention concerns a method and a control device for automatically controlling the heat dissipation {dot over (q)} in a mold 200 for casting metal. The heat dissipation of the side plate of a mold is automatically adjusted to a preset set point {dot over (q)}set by suitable variation of the volume flow rate {dot over (V)} of a coolant 300 through the side plate. In accordance with the invention, to avoid the necessity, when different molds are used, of adapting the control of the heat dissipation each time to different thicknesses or coatings of the side plates or to different settings of the side plates during the casting operation or during the casting of different grades of steel, the actual value for the heat dissipation {dot over (q)} during a steady-state casting operation is suitably computed on a current basis from, among other things, the difference in the temperature of the coolant 300 at the coolant outlet and the coolant inlet of the side plate 200 and material constants for the coolant.

Abstract: Method and apparatus for improving the quality and mechanical properties of an aluminum alloy engine cylinder block or other large or complex castings by providing sand molds bound with a soluble binder only at locations on said casting from which rapid cooling for directional solidification and/or improved localized mechanical properties are desired with said molds being otherwise bound at the remaining locations only with a more typical insoluble binder.

Abstract: A plurality of molds are disposed on a rotatable base. The base is rotated to move each of the molds in turn through a pouring station to an article removing station and back to the pouring station. A molten nickel chrome super alloy is poured into each of the molds in turn at the pouring station. The molds are cooled by a flow of cooling fluid. The nickel chrome super alloy articles are removed from the molds at the article removal station. The base may be continuously or intermittently rotated relative to the pouring station. Molten metal may be continuously or intermittently poured at the pouring station.

Abstract: The exemplary embodiments relate to the removal of cooling water used to cool the surface of an ingot as it is formed during casting. The cooling water is removed from the surface by directing jets of water onto the surface at an angle, and with a momentum, that causes the cooling water to be stripped from the surface when contacted with the jets, and to follow a path that prevents the cooling water from again coming into contact with the ingot surface at a position beyond the point of removal. The apparatus for this includes nozzles to create the water jets, and equipment for supplying water under sufficient pressure and rate of flow to the nozzles.

Abstract: A castable high temperature aluminum alloy is cast by controlled solidification that combines composition design and solidification rate control to synergistically enhance the performance and versatility of the castable aluminum alloy for a wide range of elevated temperature applications. In one example, the aluminum alloy contains by weight approximately 1.0-20.0% of rare earth elements that contribute to the elevated temperature strength by forming a dispersion of insoluble particles via a eutectic microstructure. The aluminum alloy also includes approximately 0.1 to 15% by weight of minor alloy elements. Controlled solidification improves microstructural uniformity and refinement and provides the optimum structure and properties for the specific casting condition. The molten aluminum alloy is poured into an investment casing shell and lowered into a quenchant at a controlled rate.

Abstract: An alloy generating hydrogen easily and safely for a long time is obtained. The alloy is obtained by melting in a blast furnace a first metal composed of one or more metals of Al, Zn and Mg and a second metal composed of one or more metals of Ga, Cd, In, Sn, Sb, Hg, Pb and Bi; and then placing the alloy in a molten state in water to cool the alloy.

Abstract: Molds 16 for casting molten materials using a directional solidification process and methods for forming a barrier layer between a liquid cooling medium 20 and a molten material of a casting process are provided. According to an embodiment, a mold 16 for casting a molten material comprises an inner surface at least partially coated with a metal oxide slurry 32 comprising metal oxide particles, wherein the metal oxide slurry 32 is capable of inhibiting a liquid cooling medium 20 from contacting a molten metal or metal alloy when the molten metal or metal alloy is disposed within an interior of the mold 16 and the mold 16 is disposed in the liquid cooling medium 20.

Abstract: The invention relates to a method and equipment for cooling anodes (4) in connection with anode casting (1), so that in the cooling unit (5), in between cooling steps, water is removed from the anode surface at least once before removing the anode (4) from the cooling unit (5).

Abstract: A mold assembly for forming a piston and method of molding a piston therewith includes a pair of mold halves moveable toward and away from one another along a linear path that is substantially perpendicular to a longitudinal central axis of the piston between an engaged position to provide at least a portion of a mold cavity for forming an outer periphery of the piston and a disengaged position to allow extraction of the piston from the mold cavity. The assembly also has a pair of cooling gallery mandrels moveable along a linear path into an engaged position between the pair of mold halves to form an undercut cooling gallery of the piston. The pair of cooling gallery mandrels are movable to a disengaged position to allow extraction of the piston vertically along the axis.

Abstract: An investment casting process utilizes rapid cooling during solidification to achieve a desired final microstructure. A molten high temperature aluminum alloy is poured into a ceramic shell mold. The ceramic shell mold is then lowered into an oil bath held in a quenching tank to rapidly cool the molten material. Thus, solidification takes place quickly via rapid extraction of the latent heat of the metal by the quenching oil bath. The rapid solidification achieves a uniform fine microstructure in an as-cast component.

Abstract: An investment casting process utilizes rapid cooling during solidification to achieve a desired final microstructure. A molten high temperature aluminum alloy is poured into a ceramic shell mold. The ceramic shell mold is then lowered into an oil bath held in a quenching tank to rapidly cool the molten material. Thus, solidification takes place quickly via rapid extraction of the latent heat of the metal by the quenching oil bath. The rapid solidification achieves a uniform fine microstructure in an as-cast component.

Abstract: A cooling passage is formed to have a helical configuration so that a flow rate of a cooling medium supplied to the cooling passage is controlled to be in an optimum cooling region. Accordingly, the contact surface area and the cooling volume of cooling water are decreased respectively. Further, it is possible to stably obtain an optimum casting quality with ease.

Abstract: Method and device for casting cast iron including a metal chill mold (100) having outer walls (206, 208, 210) and inner walls (212, 213, 220). The inner walls are in contact with a mold (300). The device further includes pressurizing means (400) for applying a variable pressure on the outer walls (206, 208, 210) of the chill mold, in order to control changes in volume of molten material enclosed by the chill mold, and chill mold cooling means (500) for variable cooling of the inner walls (212, 213, 220) of said chill mold.

Abstract: Processes for providing enhanced thermal properties of tooling, particularly metal and metal/ceramic molds, made by solid free form fabrication techniques, such as the three dimensional printing process, and the tooling made by these processes are disclosed. The methods of enhancing thermal properties include incorporating integral contour coolant channels into the mold, adding surface textures to the coolant channels, creating high thermal conductivity paths between the surfaces and the coolant channels, and creating low thermal inertia regions in the mold.

Abstract: A grain starter capable of nucleating a multiplicity of grains in a casting is positioned within a mold. The mold is filled with molten metal and a solidification interface is caused to pass from the grain starter through the molten metal by immersing the mold in a cooling bath to form a casting that has a multiplicity of grains nucleated by the grain starter.

Abstract: A liquid metal cooled directional solidification process provides improved solidification characteristics at the solidification front. In the process, a mold is filled with molten metal; and a solidification interface is caused to pass through the molten metal by progressively immersing the mold into a cooling liquid. The cooling liquid is a eutectic or near eutectic metal composition. A directional solidification furnace includes a heating furnace, a liquid cooling bath and a mold positioner. The heating furnace has an open bottom end through which a heated mold containing molten metal is lowered from the furnace. The liquid cooling bath comprises a molten eutectic or near eutectic metal composition positioned beneath the open end of the furnace. The mold positioner gradually lowers the heated mold from the furnace, through the open end and immerses the mold into the liquid cooling bath.

Abstract: A cast-on method and its apparatus for joining battery plates to a post in which heat capacity of a mold for forming a post and a strap is less than five times of heat capacity of metals to be introduced in the mold. The mold is made of materials having less linear thermal expansion coefficient preferably less than 18×10−6/° K. The mold may be dipped into calmly flowing molten metal keeping a constant level.

Abstract: The invention concerns thermoregulated molds and tools with a defined, fine-branched and point-focal interior heat-transferring conduit, process for their production, their use and process for the thermoregulation of molds and tools. According to the invention, these molds and tools contain on the inside a thermoregulating conduit in configuration of an arterial vessel system, through which an appropriate heat-transferring medium flows for heating or for cooling. The production of these molds and tools is conducted by means of rapid prototyping processes, particularly stereolithography.

Abstract: A casting apparatus has within a heating chamber (6) a mold (5) which can be moved out of the heating chamber (6) into a molten cooling metal (10) disposed beneath it. As heat insulation between the heating chamber (6) and the molten cooling metal (10) a thermal insulation layer (13) floating on the molten cooling metal is provided through which the mold (5) dips into the molten cooling metal (10). To prevent clumping within the thermal insulation layer (13) a rake or stirrer (19) is provided, which is driven by a shaker (17) and whisks or stirs the thermal insulation layer.

Abstract: Steam explosions can be prevented or mitigated during a metal casting process by the placement of a perforated flooring system in the casting pit. An upward flow of compressed gas through this perforated flooring system is introduced during the casting process to produce a buffer layer between any spilled molten metal and the cooling water in the reservoir. This buffer layer provides a hydrodynamic layer which acts to prevent or mitigate steam explosions resulting from hot, molten metal being spilled into or onto the cooling water.

Abstract: Methods of manufacturing fully annealed metal anodes are disclosed. The methods contemplate supplying metal and heating the metal until it has obtained a molten state. The molten metal is permitted to flow into a die and transported therethrough where it is cooled until it solidifies. The flow rate of the metal through the die and the extent of cooling are selected such that a fully annealed metal anode is obtained.

Abstract: A method of casting a turbine wheel of a metal alloy, wherein there is generated a columnar grain structure parallel to the leading and trailing edges of the vanes, by directional solidification of the metal from the central aperture in the wheel outward to the vane tips. A form with cavity to receive therein the molten metal has a thin walled core in the center, with the core wall outer surface in place to provide one wall of the cavity. A heat transfer medium in fluid form is circulated through the core, thereby cooling the poured metal by heat transfer from the inner ends of the vanes outward to the tips.

Abstract: A mold for casting metal ingot sows having an aspect ratio of at least 4:1. The mold comprises a bottom wall from which a side wall extends upwardly and outwardly and from which heat transfer structure extends downwardly for transferring heat away from the bottom wall.

Abstract: A method of manufacturing a thick-walled container casting of a cast iron with a spheroidal graphite comprises forming an inflexible mold spaced between an inner cylindrical dead mold core and an outer mold arranged over the dead mold core, filling the mold space through a gate from an end thereof while cooling particularly the inner mold surface of the mold ajacent the dead mold over the amount of a cooling of a usual sand casting, and dimensioning the gate so that the cast iron solidifies in the gate before the eutectic solidification of the casting sets in. The device comprises an inner cylindrical dead bolt core which has a bottom end and a closed top end and an outer cylindrical mold positioned over the inner core with its top spaced from the top end of the inner dead mold core. The bottom open ends of the inner and outer cylindrical molds are closed by means which define a mold filling closure having a gate dimensioned so that the filling of the mold will effect first the solidification in the gates.

Abstract: A rotary take-off system comprising an apparatus for removing manufactured objects such as cast metal anodes from a first work station and transporting these objects to a second work station. The first station, at which the object is manufactured, may preferably be a mold located upon a rotatable casting wheel, while the second work station is preferably a quenching medium for cooling and temporarily holding the manufactured object. After the object is manufactured at the first work station it is then transported through an arc of approximately 180.degree. by a pair of rotatable arms to the second work station for further processing. The arms are coupled to a motor which is operated in order to cause the rotation thereof. Within the quenching medium, a pair of pivotably connected hydraulic push arms is positioned, which accept the anode as it drops from the rotatable arms and which thereafter facilitate the sliding and stacking of the completed anodes to a rear portion of the quenching medium.