Abstract: A two-stage investment removal apparatus for removing investment material from an investment casting includes first and second stage sub-assemblies operative for different impacting actions. The first stage sub-assembly includes spaced drive rollers for rotating the investment flask on its side, and a pneumatic hammer which engages the side wall of the investment flask for imparting impact energy to the investment flask while the flask is being rotated. The flask is placed in a protective sleeve which more evenly distributes the impact forces around the side wall of the flask during rotation. The second stage sub-assembly includes a tubular chamber, and a spring-biased seat in the chamber for receiving the bottom end of the central casting trunk when the flask is positioned on the seat. The chamber includes radial spring arms for centering the flask and casting trunk on the seat.

Abstract: A casting shake-out unit has an outer cylinder and an inner cylinder. The inner cylinder is made of a plurality of interfitting segments which interlock and cooperate with each other to prevent a segment from falling out of the completed inner cylinder. Each segment includes tongues extending from opposing edges of the segment's body and pockets formed in the body. The pockets of one segment receive at least a part of the tongue of a neighboring segment.

Abstract: A method and apparatus for the accurate formation of a three-dimensional article comprises providing a supply of substantially uniform size droplets of a desired material wherein each droplet has a positive or negative charge. The supply of droplets is focused or aligned into a narrow stream by passing the droplets through or adjacent an alignment means which repels each droplet toward an axis extending through the alignment means. The droplets are deposited in a predetermined pattern at a predetermined rate onto a target to form the three-dimensional article without a mold of the shape of the three-dimensional article. A supply of support material is provided in a predetermined pattern adjacent the deposited droplets. The support material receives a further supply of droplets which form a part of the three-dimensional article.

Abstract: In order to effectively enhance the overall efficiency in casting operations, a process and system for cooling and cleaning a casting is disclosed. The process and system include removing the casting from a molding machine after it has been formed. The casting is then moved to a punch-out station for removing it from a sand mold. Next, the casting is moved to a shake-out station for shaking residual sand from it. The casting is then conveyed away from the shake-out station on a cooling conveyor. Next, the temperature of the casting is monitored at or near a downstream end of the cooling conveyor. The casting is then transferred from the cooling conveyor into a vibratory cooling drum where it is further cooled. In addition to these unique aspects, the process and system includes controlling the rate of cooling of the casting within the vibratory cooling drum.

Abstract: A device for detecting galling which may produce deformations during an ejection process of die castings from a die. The device includes a setting device for storing a predetermined set value, the predetermined set value including an upper limit of acceleration of an ejector plate during the ejection process and a predetermined time period during the ejection process. An accelerometer is disposed to the ejector plate for measuring the acceleration thereof during the ejection process. A computing device is provided for comparing the acceleration measured by the accelerometer with the predetermined set value and outputting a warning signal when the acceleration measured at the accelerometer exceeds the upper limit during the time period. Thus, timely detection of galling can result.

Abstract: A method and apparatus are described for the production of piston castings, and, in particular, a die construction and method of use thereof are described, the die having a crown forming part (18) separable from a skirt forming part (12). In the method, when solidification of the casting occurs to an extent at least enabling the separation of the skirt forming die part therefrom to be allowed, and the die parts (20, 22) are separated, the casting is retained by the crown forming part (18) of the die. After a subsequent process step, such as the solidification of the remainder of the piston casting, and or the cooling of the piston casting by an air blast (64), the solidified piston is removed from the crown forming part of the die.

Abstract: A die-casting machine is described which includes at least one cylinder/piston assembly. Each assembly has main, ejector and core pistons and cylinders. The main cylinder is stationary and holds a piston which reciprocates to bring the molds together for metal injection or apart for releasing a die casting. A portion of the interior of the main piston constitutes an ejector cylinder having an ejector piston and a portion of the interior of the ejector piston constitutes a core cylinder having a core piston. The present invention is more compact and less complex than conventional die-casting machines.

Abstract: The apparatus for removing investment material from an investment flask casting includes a spring-biased seating assembly, a centering assembly having spring-biased shoulder mounts, a vertical impact assembly, and a pair of opposing horizontal impact assemblies. The vertical and horizontal impact assemblies work simultaneously and in combination with the spring-biased seating assembly and the spring-biased shoulder mounts to transmit linear dynamic and high frequency vibratory impact energy to the investment flask casting wherein the apparatus effectively and quickly removes virtually all of the investment material therefrom. The investment apparatus further includes an investment collection system for collecting waste investment material for subsequent disposal.

Abstract: A heat-resistant cast steel having a metal matrix substantially consisting of a ferrite phase and a pearlitic-colony phase has a composition consisting essentially, by weight, of C: 0.05-0.25%, Si:2.5-3.5%, Mn:2% or less, Cr:4-8%, N:0.05% or less, and Fe and inevitable impurities: balance, as well as at least one selected from the group consisting of (i) W and/or Co:0.1-2%, (ii) a rare earth element and/or Y:0.1% or less, (iii) Mg and/or Ca:0.005-0.03%, and (iv) B:0.001-0.01%.

Abstract: The invention is a method of forming a spherical bearing shell comprising an overlay casting process which utilizes a ceramic insert having a semi-spherical close-tolerance outer surface with a casting sprue opening therethrough and lubrication ribs on said outer surface. The ceramic insert is placed within structural bearing housing, defining an overlay cavity therebetween which is then cast with a molten bearing alloy into the sprue opening of the insert to a level above the height of the overlay cavity. The sprue opening is then back-drilled so that the ceramic insert and plug of bearing alloy can be separated from the bearing housing and overlay surface leaving a semi-spherical bearing surface with lubrication grooves cast therein.

Abstract: A flexible product, more particularly an information-carrying disc, is removed from a carrier plate, more particularly a mold, by creating a partial vacuum at the side of the product facing away from the carrier plate. While the product is being displaced in a direction facing away from the carrier plate under the influence of the partial vacuum, the product is guided in such a way that it is displaced over the greatest distance at two opposite ends and the displacement of the parts of the product situated between these ends decreases gradually towards the center of the product.

Abstract: A die casting method using a die casting machine having a fixed die, a movable die and an injection mechanism includes the following steps (a) through (d) of: (a) clamping the movable die to the fixed die; (b) injecting by the injection mechanism the molten metal formed of alloy material into a cavity while the fixed die and the movable die are being clamped to each other; (c) separating the movable die from the fixed die before the alloy material is completely coagulated and shrunken in the cavity; and (d) taking out a product formed of the alloy material from either the movable die or the fixed die after the movable die has been separated from the fixed die.

Abstract: In a structure comprising an ultra-sharp silicon tip coated with a layer of material, the silicon is removed from the structure. The remaining material is utilized as a mold. Metal deposited in the mold replicates the original silicone tip. In this way, ultra-sharp all-metal tips suitable, for example, as field-emitter sources are provided.

Abstract: The present invention concerns a container for a fusible material such as gallium. The material is introduced to the container in liquid form and solidifies therein. The body contains two intersecting tear strips making it possible to easily strip the block of solidified material from the container. Each of the tear strips extends past its point of intersection with the other tear strip to maximize the extent to which the container is opened up. The material can thus be removed from the container with minimal handling and risk of being contaminated.

Abstract: A molding process and an apparatus wherein the molds produced in a molding machine are sent past a casting apparatus where casting takes place. Thereafter, the molds with the molding boxes surrounding them, pass through a primary cooling line, at the end of which molds and molding boxes are separated. The molding boxes are returned to the molding machine, while the sand molds with the castings pass through a secondary cooling zone for further cooling. The process allows for a substantially smaller number of molding boxes than previously known molding processes.

Abstract: A mold casting process comprises, after pouring of a molten metal into a mold, rapidly cooling that surface layer of a cast product which is in contact with a mold, and releasing the resulting product from the mold when the surface layer thereof has been converted into a shell-like solidified layer. Such process is used for casting a mechanical part blank and apparatus for carrying out the process is provided.

Abstract: A die casting apparatus for forming rotors for electric motors. The apparatus includes a frame having at least two opposed stationary pressure plates and a rotating turret rotatively mounted betewen these stationary plates. The turret includes three apertures at three equally spaced locations around the turret. Tooling is arranged at each of the respective locations for forming a rotor. Compensating and casting tooling is located at a first station, pin pressing and trimming tooling is located at the second station and unloading and loading tooling is located at the third station. The operations at the respective stations proceed simultaneously. The operations are selected so that the combined operations of each of the stations will take approximately equal amounts of time.

Abstract: In production of a gap spacer for magnetic heads in electric and electronic appliances, accumulation of a non-magnetic material insoluble to acids or alkalis on a thin base soluble to these solvents is employed with use of a proper mask as a substitute for the conventional rolling process. Stable growth in thickness of the non-magnetic material during the accumulation process assures highly precise thickness uniformity of the product via easy time control of the process and absence of the rolling process allows broader freedom in choice of the material.

Abstract: A vertically adjustable support frame (10) with chain clamps (12) supports a mold (14) containing an ingot (16) in alignment with a ram cylinder (18). Rolls (34) receive the ingot and transfer it to rolling rolls (38). A belt grinder (46) traverses the length of the rotating ingot to grind the circumference.

Abstract: An aluminum metal matrix composite comprises an aluminum metal matrix embedding a second filter, such as a ceramic second filler, and is formed by contacting, for example, a molten aluminum metal with a permeable mass of second filler within a ceramic impervious mold formed by growing a polycrystalline oxidation reaction product into a first filler. By hermetically sealing the second filler within the mold with a body of molten aluminum metal, the latter spontaneously infiltrates the mass of second filler at moderate temperatures, e.g. about 900.degree. C., without need of any other infiltration expedients. The molten mass containing the infiltrated ceramic filler is solidified to provide the metal matrix composite which may be recovered from the mold.

Abstract: In a horizontal mold clamping and vertical injection type die cast machine, when molds are opened, a product is held by a product holding device. When mold opening is completed, the product is pushed out by a product push out device mounted to a stationary metal mold side of the machine.

Abstract: A mold or parts of the mold are removed from a casting following solidification and cooling by immersing the casting with mold or mold particles still attached in a liquid such as oil or water and focusing shock waves onto interface portions to obtain ablation and spalling of the mold material to be removed from the casting.

Abstract: Molten metal is sprayed onto a rotational mandrel which oscillates axially and an axial translatory extraction motion is superimposed for removing the built-up hollow from the mandrel.

Abstract: A foundry machine for forming molds or cores from a molding material such as sand provides completely automated loading and unloading of tooling elements (24). The tool elements (24) comprising a sand magazine (36), blow plate (34), combined gassing manifold and top ejector unit (32), upper mold box (30), lower mold box (28) and bottom stool (26) are automatically transferred, in stacked, separable relationship, by tracks (40) to a vertically displaceable, work table. Vertical displacement of the work table (42) sequentially elevates the tooling elements (24) to positions within a mainframe (10) where automatically operated clamping means secure the appropriate tooling elements (24) in respective operating positions. The gassing manifold (32) includes an ejector pin assembly (274, 280) mounted therewithin.

Abstract: An apparatus usable for cleaning foreign material from the internal and external surfaces of a part, including a container of particulate media, a vibration generator for the container which creates an amplitude and frequency which will fluidize the media, and means for suspending the part in the fluidized media. The suspending means is vibrated at an amplitude and frequency different from the amplitude and frequency of the container whereby the fluidized media will clean the foreign material from the internal and external surfaces of the part.

Abstract: A method of casting or moulding an article having an internally screw-threaded hole comprises introducing casting or moulding material into a mould cavity around a core pin formed with segments of a screw thread separated by flutes and also around withdrawable flat core members projecting into the mould cavity with their leading ends fitting snugly into the flutes. The segments of screw thread form the male image of segments of the required female thread. When the casting or moulding material has set first the core members are withdrawn from the mould cavity then the core pin is rotated to bring the screw-threaded segments into the positions formerly occupied by the flutes and the pin is withdrawn axially from the mould cavity. Finally the article is removed from the mould cavity.

Abstract: A method of making die castings of one metal with a row of spaced fingers of another metal mounts the fingers in slots of an elongated holder with portions of the fingers projecting beyond the holder. The holder is mounted in a die casting machine having a molding cavity surrounding the projecting portions of the fingers. Metal is die cast around the projecting portions of the fingers to form a frame. The casting and the holder are ejected from the die casting machine, and the holder is stripped from the fingers. The method is especially useful for making relays for teleprinters and the like where electrical input produces mechanical movement and where the fingers become cores of electromagnets with the die casting metal being non-magnetic.

Abstract: A method for forming metal base composite use a retainer made of water soluble salt with a high melting point. Molten metal and a reinforcement are compounded in the retainer and then solidified. After solidification the retainer is dissolved away by water.

Abstract: Cores made from Alumina and other non-Silica based refractories can be made readily leachable in fused anhydrous caustic alkalis by the addition to the core of a small quantity of a material containing a Hydrogen donor group. The Hydrogen donor group is one which produces uncombined, or nascent Hydrogen when the ceramic is contacted with the anhydrous caustic alkali. Such groups are Hydroxyl groups, Hydrides or chemically combined water. In one disclosed example Silica which contains traces of water is added to high fired Alumina to provide the Hydrogen donor group. Only 2% to 3% Silica addition is required to make the Alumina readily soluble in the fused alkali.

Abstract: Ceramic core materials are selectively dissolved from light metal, e.g. Aluminium or light alloy, e.g. Aluminium alloy castings which are themselves susceptible to attack by caustic alkali solutions, by providing the core material with a substance containing Hydrogen donor group which is capable of producing nascent hydrogen and contacting the core with fused anhydrous caustic alkalis. By this means Silica cores can be removed from Aluminium alloy castings, or a ceramic containing a hydrogen donor group can be selectively dissolved from one that does not, e.g. a Silica disposable pattern from within an Alumina mould containing an integral Alumina core.

Abstract: A method for removing a casting from a sandbox, the method comprising the steps of rotating a sandbox including therein a casting embedded in sand so as to dump the sand from the sandbox, holding the casting while the sand is being dumped so as to maintain a substantially stationary relationship between the casting and the sandbox, and removing the casting from the sandbox after a portion of the sand has been dumped.

Abstract: A method for electrohydroblasting of castings in a liquid medium with a view to removing core and molding sand, according to which castings are subjected to a series of electrohydraulic shocks and at the same time set in reciprocating motion. The reciprocating frequency of the castings and the length of their stroke are sufficient to produce a flow of liquid in the internal channels of the castings and thus remove core and molding sand therefrom. The method is carried out with the aid of an apparatus which comprises a casting-reciprocating mechanism interacting with an electrode-positioning mechanism so that the movement of the castings is synchronized with that of the electrode.

Abstract: A method and tool for manufacturing a scroll for use in a scroll type fluid displacement apparatus is disclosed.

Abstract: In a method of forming a thin (<2 .mu.m) unbacked metal foil having a desired curviplanar shape, a soluble polymeric film, preferably comprising polyvinyl alcohol, is formed on a supporting structure having a shape that defines the desired shape of the foil product. A layer of metal foil is deposited onto one side of the soluble film, preferably by vacuum vapor deposition. The metallized film is then immersed in a suitable solvent to dissolve the film and thereby leave the metal foil as an unbacked metal foil element mounted on the supporting structure. Aluminum foils less than 0.2 .mu.m (2,000 .ANG.) thick and having an areal density of less than 54 .mu.g/cm.sup.2 have been obtained.

Abstract: A method for forming metal articles, such as rods and tubes by aspiration casting is provided in which a hollow frangible mold, such as a glass tube, is immersed at one end in a molten metal bath, a vacuum is applied to the other end controlled with respect to temperature of the molten metal so as to substantially fill the mold with a minimum of turbulence, the filled mold is withdrawn from the metal and the frangible mold is shattered to remove it from the metal article formed within.

Abstract: A method for manufacturing a scroll for use in a scroll type fluid displacement apparatus is disclosed.

Abstract: A method for replicating laser mirror surfaces is described which comprises careful preparation, as, for example, by single point diamond turning, on a master block, of a master surface having the contour corresponding to the desired laser mirror surface, vapor depositing onto the master surface a thin metallic layer, and vapor depositing the laser mirror faceplate material to the desired thickness. The selected master block material has a coefficient of thermal expansion mismatch with that of the deposited faceplate material so that the master block shrinks and separates away from the deposited faceplate upon cooldown from the vapor deposition temperature.

Abstract: A method for the die casting of end rings and conductor bars in rotors employing a die casting machine having a compensator mechanism comprising a compensator sleeve and a compensator for reciprocal movement along a first axis. A coaxially movable die plate closes off one end of the compensator sleeve to form a die cavity for casting. A plurality of lamination stacks, each held together by a removable stacking pin, are stored on an inclined loading rack positioned laterally on one side of the compensator mechanism. A few of these stacks roll down inclined planes into the compensator sleeves. The compensator pushes the stacks forward into abutment with the die plate and a charge of molten material is injected into the die cavity. The die plate then moves axially away from the compensator and a retriever moves perpendicular to the first axis to an unload position between the compensator sleeve and die plate.

Abstract: Apparatus for transmission of sonic energy to the processing of work wherein the sonic energy is transmitted through a vibratory member to a fixture having spaced abutment surfaces in which the clearance between one abutment surface and the adjacent surface of the work piece, while the work piece is at rest on the other abutment surface, is equal to .+-.50% of the amplitude of the vibrations at the point of attachment of the fixture to the vibration generator.

Abstract: Apparatus and method for producing a die cast article, such as a gear wheel having helical teeth, in which the die cavity is defined by fixed elements and a rotatable element. On completion of the casting the cast article can be ejected from the casting cavity on relative rotation between the fixed elements and rotatable element so that the cast helical teeth of the article can be removed in an undamaged condition.

Abstract: Sand bales containing castings are removed from poured foundry molds by clamping together in a horizontal position the molding boxes containing the sand bales, by supporting the sand bales from below independently of the molding boxes, and by applying to the molding boxes jarring or accelerative forces acting in a vertical direction with a magnitude exceeding the static frictional forces which exist between the sand bales and the molding boxes, with these forces being applied while the sand bales are supported thereby to cause the sand bales to move out of the molding boxes. In one aspect, the sand bales are supported from below by a force lower than the weight of the bales thereby to permit the bales to drop out of the molding boxes while the accelerative forces are applied to the molding boxes in an upward direction. Conversely, the sand bales may be lifted upwardly out of the molding boxes with accelerative forces being applied to the molding boxes in a downward direction.

Abstract: An aluminium-silicon alloy casting in which zones formed so as to have a particularly fine-grained structure are cooled by way of individual thin-walled mould wall portions, which are prevented from dissolving completely by the melt and are intermetallically bonded to the casting and are detachable from the finished casting only in a destructive manner.

Abstract: There is proposed herein a method and apparatus for cooling, drying and separating casting pieces and molding sand and wherein the apparatus includes an opening that extends lengthwise therethrough, the cooling operation being conducted by inducting air in a rotary drum that is contiguous to a first rotary chamber that is in juxtaposition relative to a stationary chamber. The sand is caused to pass through perforated areas within the apparatus while the casting pieces continue through the axial opening in the stationary chamber. A perforated divider wall disposed between the first rotary chamber and the stationary chamber permits passage of sand to a discharge valve and vents air to atmosphere. In a further embodiment of the invention a polygonal sieve is disposed between the rotary chamber and the stationary chamber, said sieve being a truncated pyramid and provided with guide foils.

Abstract: A positioning apparatus for a centrifugal casting machine having an articulated mold that is mounted for rotation in a cantilevered manner on a drive shaft. The positioning apparatus includes a pair of pillow block bearings having arcuate bearing races that operate to allow the drive shaft to be tilted within a predetermined angular range relative to its longitudinal axis. In addition, the positioning apparatus includes a plurality of locking pins each of which are mounted to cooperate respectively with one of a plurality of positioning members mounted on a rotatable mold-supporting face plate of the casting machine. Operation of the lock pins into engagement with the positioning members moves the face plate into a predetermined position relative to its axis of rotation, following a casting cycle of the machine, so that segments of the centrifugal mold can be radially stripped from an article cast therein without unduly distorting the cast article.

Abstract: Disclosed is a ceramic knock-off apparatus for automatically removing the ceramic coating from investment casting molds having a plurality of arms. Prior to operation, a ceramic covered mold is loaded into a receptacle on a turntable and rotated to a starting position thereby placing one of the arms of the ceramic covered mold directly under the head of an air hammer. The apparatus automatically removes the ceramic coating from each arm of an investment casting mold by lowering the air hammer until it engages the first arm of the mold, operating the hammer thereby vibrating that arm of the mold and causing the ceramic coating to break and fall off, raising the hammer, automatically rotating the turntable until the next arm of the mold is aligned under the air hammer, and lowering the hammer to engage the next arm. This cycle is repeated until the ceramic coating has been removed from every arm of the mold.

Abstract: Caustic solutions are employed in an autoclave process to rapidly remove cores made of .beta.-Al.sub.2 O.sub.3 from directionally solidified eutectic alloy and superalloy materials.

Abstract: A weakly acid solution of either NH.sub.4 NO.sub.3, NH.sub.4 Cl, NH.sub.4 HSO.sub.4, CH.sub.3 COOH or equimolar CH.sub.3 COOH -- CH.sub.3 COONa is employed to remove cores of either Y.sub.2 O.sub.3 or Sm.sub.2 O.sub.3 from castings of advanced superalloy materials. A molten salt bath may be used thereafter to remove reaction products formed by the reaction of the materials of the core and the metal casting.

Abstract: A process for casting or molding a single internal thread at the same time that the desired product is cast or molded. The desired thread configuration is defined by two aligned and abutting identical core pins. Each of the pins has a protruding portion in the shape of a helical ramp extending through an angle of less than 360.degree.. The ramp has an outer diameter and pitch corresponding to the diameter and pitch of the desired internally threaded surface to be formed. The protruding portion of each core pin includes a vertically oriented surface extending between the ends of the ramp. A peripheral edge groove extending along the outer edge of the ramp defines the desired thread configuration. The aligned core pins are placed within a recess formed by mating portions of a die block to define the shape of the desired product.

Abstract: A method of making a brake shoe having a curved table section and at least one rib section disposed on the concave side of the table section, generally including casting the brake shoe in a mold having cope and drag sections so that the axis of curvature of the table section thereof is disposed substantially parallel to the parting plane of the mold sections whereby no draft or parting ridge is formed on the outer curved surface of the table section.

Abstract: Method and apparatus for casting a metal article in a mold at least as long as the article, utilizing a cooled mold of elongated form having top and bottom portions. The method includes the steps of introducing molten metal from a source through the bottom portion of the mold, flowing molten metal into the mold so as to form a solidifying casting shell which .Iadd.a .Iaddend.during casting occupies at least 40% of the cross-sectional mold area and .Iadd.a .Iaddend.has a molten core, and flowing molten metal from the source through the core towards the mold top .Iadd.at a filling rate, dependent on the mold cross sectional area, such that the product produced will have a relatively fine grained structure throughout the cross-section thereof.Iaddend..