Introduction Control Or Manipulation Of Charge Patents (Class 164/133)
  • Patent number: 6640877
    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.
    Type: Grant
    Filed: June 27, 2002
    Date of Patent: November 4, 2003
    Assignee: Howmet Research Corporation
    Inventors: Mark L. Soderstrom, Bart M. Kilinski, John R. Brinegar, Brad J. Murphy
  • Patent number: 6637496
    Abstract: Apparatus for making a cast article includes a rotary table with a drive for indexing the rotary table to a plurality of rotational positions. A molten metal supply apparatus is placed at a first fixed location adjacent to said rotary table. A plurality of casting machines are supported at predetermined spacings on the rotary table, each respective casting machine having a respective holding furnace feeding a respective stalk tube and having a molten metal inlet port for receiving molten metal from the molten metal supply apparatus when the respective casting machine is indexed to a fill position adjacent the first fixed location. Each respective casting machine is adapted to receive one or more molds and has an open mold configuration and a closed mold configuration.
    Type: Grant
    Filed: November 30, 2001
    Date of Patent: October 28, 2003
    Assignee: Hayes Lemmerz International, Inc.
    Inventors: Robert L. Macheske, Thomas J. H. Rozich, Alan P. Gould, Daniel D. Minor, Kenneth D. McKibben
  • Patent number: 6637497
    Abstract: Mold filling and feeding device (400) and process including using refractory filter cloth (202) to seal a mold line (100), in continuous conveyance, to a multi-stage pressurized filling and feeding device. The mold line (100) consists of vertically parted or horizontally parted green sand molds (101), or an extruded bed of media carrying various types of molds, including green sand, nobake, lost foam, investment casting shells, etc. These molds are bottom or side filled while moving for increased production rates. Feeding under pressure, while moving, is a second operation that improves casting integrity. The process includes a new and more efficient method of treating iron with magnesium for compacted graphite or ductile iron. A stitch (242) of filter cloth (202) holds modifying alloy (630) to the molds (101). A vacuum and pressure controlled column (550) provides consistent flow to thin walled castings, and pressurized feeding for heavy castings. Radiant energy losses are contained in the automatic system.
    Type: Grant
    Filed: May 8, 2002
    Date of Patent: October 28, 2003
    Inventor: David J. Herron
  • Publication number: 20030178169
    Abstract: A method for uphill/low-pressure casting, especially of light metal alloys, with a casting table having a flow-through opening, with a casting furnace lying below the casting table with a riser pipe forming an upwardly open mouth opening, with a mould having a base plate which has a downwardly open pouring-in opening; the mouth opening is positioned against the flow-through opening in a sealing fashion from below, the mould is brought with its pouring-in opening over the flow-through opening, melt is conveyed from the casting furnace via the riser pipe into the mould until it is filled, the mould is displaced horizontally on the casting furnace with open melt-filled communication between the casting furnace and the mould until the pouring-in opening is closed by the casting table below and the flow-through opening is closed by the base plate above, the melt is allowed to drop in the riser pipe as far as below the mouth opening.
    Type: Application
    Filed: May 29, 2003
    Publication date: September 25, 2003
    Inventors: Alexander Fischer, Wolfgang Mller
  • Publication number: 20030173052
    Abstract: A metal flow system, for use in casting aluminium alloy using a pressure casting machine, is provided by a component of a die or mould assembly, for the machine, which defines a die cavity. The component defines at least part of an alloy flow path for the flow of aluminium alloy from a pressurized source of substantially molten aluminium alloy of the machine to the die cavity. The flow includes at least one runner and a controlled expansion port, referred to also as a CEP, which has an inlet through which the CEP is able to receive aluminium alloy from the runner and an outlet through which aluminium alloy is able to flow from the CEP for filling the die cavity.
    Type: Application
    Filed: February 21, 2003
    Publication date: September 18, 2003
    Inventors: Morris Taylor Murray, Matthew Alan Cope
  • Patent number: 6619369
    Abstract: A process for producing a thin die-cast molded article of an aluminum material having a portion having a thickness in the range of 0.4 to 1.2 mm using a mold having a gate having an opening of 0.2 mm or greater and the same as or smaller than the thickness of the portion of the molded article separated from a gate portion, members constituting the gate having been treated by nitrogenation at the surface. The thin die-cast molded article of an aluminum material can be produced efficiently with excellent flow of the melted metal of the aluminum material through the gate portion.
    Type: Grant
    Filed: August 8, 2001
    Date of Patent: September 16, 2003
    Assignee: Try Co., Ltd.
    Inventor: Akira Takayanagi
  • Patent number: 6598658
    Abstract: A closed system and method that includes a source of pressurizeable molten lead connected to a mold having a mold cavity therein with the mold maintainable at sufficiently low temperature so that a charge of molten lead located in the mold cavity solidifies to thereby form a solidified casting in the mold cavity. A housing having a runner, is maintainable at sufficiently high temperature to maintain the molten lead in a molten state so that the mold cavity can be refilled with a fresh charge molten lead when a solidified casting is removed therefrom without introducing air to the closed system. A shut-off valve, having an open position to allow a charge of molten lead to flow into the mold cavity and a closed position to prevent molten lead from flowing out of the runner as the molten lead in mold cavity solidifies with the shut-off valve configurable to intensify the pressure of the lead in the mold cavity.
    Type: Grant
    Filed: May 16, 2002
    Date of Patent: July 29, 2003
    Assignee: Water Gremlin Company
    Inventor: Robert W. Ratte
  • Publication number: 20030136541
    Abstract: A process for manufacturing highly wear and fatigue resistant steel components for power tools includes melting and mixing together a readily available base steel and alloying elements. The molten steel is cast into near-net-shape in an investment casting process. This method is cost competitive with forming the same component from steel with fewer alloying elements. In particular, clutch plates for a drill/driver or screw gun can be formed in this manner from a steel containing relatively large amounts of nickel and chromium, such as SAE 9310 steel, or from a steel containing a relatively large total amount of molybdenum and tungsten, such as AISI M2 steel.
    Type: Application
    Filed: February 11, 2003
    Publication date: July 24, 2003
    Inventors: Bimal Kumar Chaterjee, Alan Phillips, John Robert Kriaski, Daniel Paxton Wall
  • Patent number: 6591895
    Abstract: Apparatus for pouring of molten metal from a vessel onto the gating system of a mold includes a shield assembly that diverts any abnormal flow of molten metal occurring between normal flow of molten metal onto the gating system when molds are indexed for pouring. The shield assembly protects sensitive components of the mold, such as the gating and casting patterns in a lost foam casting process, from abnormal flow of molten metal.
    Type: Grant
    Filed: September 20, 2001
    Date of Patent: July 15, 2003
    Assignee: Inductotherm Corp.
    Inventors: Emad Tabatabaei, William R. Pflug
  • Patent number: 6585031
    Abstract: In a control method of the injection molding in accordance with the invention, in the process of injecting molding a low-melting-point alloy, an upper limit Qmax and a control lower limit CQmin of a quantity of material detained in a cylinder 12 are set to eliminate an excess or a shortage of the quantity of material detained in the cylinder 12. A material in a quantity greater than shot weight Qout is fed continuously into the cylinder until the upper limit is reached, while the material in a quantity less than the shot weight is fed into the cylinder until the lower limit is reached, thereby automatically maintaining the quantity of material detained in the cylinder within the range between the upper and lower limits. Accordingly, the down time due to the instability of metering in a molding machine can be reduced, and manpower for adjustment of conditions is not required, thereby making it possible to curtail the cost.
    Type: Grant
    Filed: February 12, 2002
    Date of Patent: July 1, 2003
    Assignee: The Japan Steel Works, Ltd.
    Inventor: Kengo Takeya
  • Patent number: 6581673
    Abstract: A method for producing a cast article comprising the steps of: (a)providing a casting apparatus having a mold, a casting chamber containing a molten metal under pressure and a fluid under pressure, the casting apparatus having a first supply port for supplying the molten metal to the casting chamber and a second supply port for supplying the fluid to the casting chamber; (b) supplying the molten metal to the first supply port; (c) supplying the fluid to the second supply port; (d) determining the amount of the molten metal in the casting chamber as a variable V1; (e) determining the amount of the fluid in the casting chamber as a variable V2; (f) determining the amount of humidity in the casting chamber as a variable V3; (g) determining the amount of the fluid entering the casting chamber as a variable V4; (h) determining the pressure of the fluid in the casting chamber as a variable V5; (i) determining the amount of the molten metal needed to produce a cast article in the mold as a variable V6; (j) determini
    Type: Grant
    Filed: December 29, 2000
    Date of Patent: June 24, 2003
    Assignee: Hayes Lemmerz International, Inc.
    Inventors: Kenneth D. McKibben, Daniel D. Minor, Robert L. Macheske, David B. Good, Thomas J. Rozich, Mark Salgat, Brandon Schnettler
  • Publication number: 20030062145
    Abstract: A system for producing cast components from molten metal. One form of the present invention includes a system for the precision pouring of molten metal within a casting mold.
    Type: Application
    Filed: April 26, 2002
    Publication date: April 3, 2003
    Inventors: Donald J. Frasier, Matthew Kush, Max Eric Schlienger, Michael Baldwin
  • Patent number: 6536508
    Abstract: A molten metal supply system (90) includes a plurality of injectors (100) each having an injector housing (102) and a reciprocating piston (104). A molten metal supply source (132) is in fluid communication with the housing (102) of each of the injectors (100). The piston (104) is movable through a return stroke allowing molten metal (134) to be received into the housing (102) from the molten metal supply source (132), and a displacement stroke for displacing the molten metal (134) from the housing (102). A pressurized gas supply source (144) is in fluid communication with the housing (102) of each of the injectors (100) through respective gas control valves (146). The gas supply source (144) is used to pressurize a space formed between the molten metal (134) and the piston (104) during the return stroke of the piston (104) of each of the injectors (100).
    Type: Grant
    Filed: December 11, 2001
    Date of Patent: March 25, 2003
    Assignee: Alcoa Inc.
    Inventors: Vivek M. Sample, Scott E. Reighard, Vincent A. Paola, Ronald G. Chabal
  • Publication number: 20030019603
    Abstract: An apparatus and method for casting metallic components is disclosed. The apparatus has a vertical parting line and a gate configuration which reduces defects within the cast components.
    Type: Application
    Filed: July 26, 2001
    Publication date: January 30, 2003
    Inventor: Warren G. Williamson
  • Patent number: 6505677
    Abstract: When casting metal articles in a mould by forcing molten metal upwardly through a filling tube by gas pressure in a closed chamber, the datum level just below that of a connector connecting the filling tube to the mould is registered by a level sensor in a sensing tube while the latter's upper end is connected to atmosphere through a vent tube. At the same moment, the pressure is measured by a pressure sensor and recorded by a control unit and maintained constant by the latter after the emptying of the sensing tube, by connecting its upper end to the chamber through an equalizing tube, until the pressure is increased to fill the mould according to a predetermined function of time programmed into the control unit. The starting point for the filling of all moulds in succession is the same, regardless of the amount of metal in the supply unit.
    Type: Grant
    Filed: November 6, 2000
    Date of Patent: January 14, 2003
    Assignee: Georg Fischer Disa A/S
    Inventors: Peter MĀ„ller Iversen, Uffe Andersen
  • Patent number: 6505674
    Abstract: An injector (100) for a molten metal supply system includes an injector housing (102) configured to contain molten metal. A molten metal supply source (132) is in fluid communication with the housing (102). A piston (104) extends into the housing (102). The piston (102) is movable through a return stroke allowing molten metal (134) to be received into the housing (102) from the molten metal supply source (132), and a displacement stroke for displacing the molten metal (134) from the housing (102). A gas supply source (144) is in fluid communication with the housing (102) through a gas control valve (146). The gas supply source (144) is used to pressurize a space (148) formed between the molten metal (134) and the piston (104) during the return stroke of the piston (104) such that when the piston (104) moves through the displacement stroke a compressed gas filled space is formed.
    Type: Grant
    Filed: September 21, 2001
    Date of Patent: January 14, 2003
    Assignee: Alcoa Inc.
    Inventors: Vivek M. Sample, Scott E. Reighard, Vincent A. Paola, Ronald G. Chabal
  • Patent number: 6474404
    Abstract: The invention relates to a method for controlling the temperature of a melt (10), preferably of a steel melt, in a distributing vessel (11), whereby the temperature of the melt is measured, the measured result is compared with a predetermined temperature range in the form of specified values, and as much heat is supplied or withdrawn from the melt such that the temperature remains inside said range. In order to control the melt temperature, a fireproof shaped part (20) which is closed on both sides and which is provided for accommodating a liquid cooled induction coil (1) is immersed in the melt (10). The transmission of heat is carried out by means of thermal conduction out of the wall of the shaped part (20) which is coupled to the induced electromagnetic field and/or by means of a direct coupling to the liquid melt (10).
    Type: Grant
    Filed: October 15, 2001
    Date of Patent: November 5, 2002
    Assignees: SMS Schloemann-Siemag Aktiengesellschaft, Didier Werke AG
    Inventors: Horst Grothe, Markus Reifferscheid, Raimund BrĆ¼ckner, Karl Heinz Schmitt
  • Patent number: 6467528
    Abstract: A fiber reinforced porous preform is positioned within a die cavity defined by upper and lower die members, and the lower die member defines a gate opening in the center portion of a water cooled shot sleeve which receives a vertically moveable shot piston. The area of the gate opening is small relative to the area of the shot sleeve, and the lower die member defines an annular recess above the inner surface of the shot sleeve for entrapping a shell of pre-solidified metal. Air vent slots extend outwardly between the shot sleeve and lower die member and are closed by the shell of pre-solidified metal. The structure prevents pre-solidified metal and air from entering the die cavity.
    Type: Grant
    Filed: May 17, 2001
    Date of Patent: October 22, 2002
    Assignee: THT Presses Inc.
    Inventors: Richard J. Kamm, Michael J. Loughman, Ronald P. Swarts
  • Patent number: 6467527
    Abstract: A method for die-casting a magnesium alloy comprises the step of casting a die cast product free of any hot tearing, shrinkage tearing and shrinkage cavity starting from a magnesium alloy comprising i) 1 to 10% by weight of aluminum; ii) at least one member selected from the group consisting of 0.2 to 5% by weight of a rare earth metal, 0.02 to 5% by weight of calcium and 0.2 to 10% by weight of silicon; and iii) not more than 1.5% by weight of manganese, and the balance of magnesium and inevitable impurities, using a cold chamber type die-casting machine, wherein a) the temperature of the molten magnesium alloy is maintained at 650 to 750°C.; b) the charging velocity of the molten metal is set at {fraction (1/100)} to {fraction (10/100)} second; and c) the intensified pressure after the charging is set at a level of not less than 200 kgf/cm2.
    Type: Grant
    Filed: June 5, 2000
    Date of Patent: October 22, 2002
    Assignee: Mitsui Mining and Smelting Co., Ltd.
    Inventors: Kohei Kubota, Koichi Satoh, Masaru Yamamoto, Yoichi Nosaka, Yasuhisa Goto, Takeshi Doi
  • Patent number: 6460605
    Abstract: A casting process for casting, in particular of sand molds provided with casting boxes, which makes it possible to keep the apparatus expense low, to save cycle material and to achieve an improved quality, consists of the intake channel extending in a plane lying essentially horizontally during casting and being provided with a bearing surface defining its port, onto which bearing surface can be sealingly positioned a fill pipeline through which the mold can be filled with metal under low pressure. A casting system to carry out the method consists of a casting machine with a pressure kettle and a fill pipeline which is connected to the intake channel lying essentially in a horizontal plane, whereby the sealed coupling of fill pipeline and intake channel is obtained through specified bearing pressure.
    Type: Grant
    Filed: April 21, 2000
    Date of Patent: October 8, 2002
    Assignee: Heinrich Wagner Sinto Maschinenfabrik GmbH
    Inventor: Herbert Grolla
  • Patent number: 6453979
    Abstract: Method and apparatus for investment casting wherein a ceramic investment mold is disposed in a chamber and communicates with a melt reservoir connected to the mold and having a reservoir volume for holding enough melt to fill the mold. The melt pour cup reservoir is communicated to the mold via an inverted loop feed gate so that the melt is fed from a lower region of the reservoir through the inverted loop feed gate to the mold upon gas pressurization of the melt in the reservoir. The loop feed gate is configured to have a loop region above the melt level in the reservoir so as to prevent melt flow from the reservoir to the more mold cavities in the absence of pressurization. While residing in the reservoir, oxides and other inclusion-forming particles in the melt can float to the upper surface of the melt, whereby the melt fed from the lower region of the reservoir to the mold via the inverted loop melt feed gate includes reduced amount of inclusion-forming particles.
    Type: Grant
    Filed: November 16, 1999
    Date of Patent: September 24, 2002
    Assignee: Howmet Research Corporation
    Inventors: Mark L. Soderstrom, Dale A. Grumm, Lester G. Striker
  • Patent number: 6453978
    Abstract: A casting process for casting, in particular of sand molds provided with casting boxes, which makes it possible to keep the apparatus expense low, to save cycle material and to achieve an improved quality, consists of the intake channel extending in a plane lying essentially horizontally during casting and being provided with a bearing surface defining its port, onto which bearing surface can be sealingly positioned a fill pipeline through which the mold can be filled with metal under low pressure. A casting system to carry out the method consists of a casting machine with a pressure kettle and a fill pipeline which is connected to the intake channel lying essentially in a horizontal plane, whereby the sealed coupling of fill pipeline and intake channel is obtained through specified bearing pressure.
    Type: Grant
    Filed: November 2, 2001
    Date of Patent: September 24, 2002
    Assignee: Heinrich Wagner Sinto Maschinenfabrik GmbH
    Inventor: Herbert Grolla
  • Patent number: 6450236
    Abstract: A method of ascending casting in a casting cavity where filling from the bottom results in a region of reduced pressure formed during the cooling in which solidification can be expected to take place last. The region is post-fed with molten material from a shortest possible feeding duct. By doing this, the consumption of casting metal is reduced, because it is no longer necessary to use a surplus of molten material to keep the bottom ingate open for feeding purposes and the consumption of mold material is also reduced because it is no longer necessary to adapt the mold to accommodate surplus molten material.
    Type: Grant
    Filed: December 8, 1999
    Date of Patent: September 17, 2002
    Assignee: Georg Fischer Disa A/S
    Inventors: Peter Iversen, Uffe Andersen
  • Publication number: 20020124986
    Abstract: In a control method of the injection molding in accordance with the invention, in the process of injecting molding a low-melting-point alloy, an upper limit Qmax and a control lower limit CQmin of a quantity of material detained in a cylinder 12 are set to eliminate an excess or a shortage of the quantity of material detained in the cylinder 12. A material in a quantity greater than shot weight Qout is fed continuously into the cylinder until the upper limit is reached, while the material in a quantity less than the shot weight is fed into the cylinder until the lower limit is reached, thereby automatically maintaining the quantity of material detained in the cylinder within the range between the upper and lower limits. Accordingly, the down time due to the instability of metering in a molding machine can be reduced, and manpower for adjustment of conditions is not required, thereby making it possible to curtail the cost.
    Type: Application
    Filed: February 12, 2002
    Publication date: September 12, 2002
    Applicant: THE JAPAN STEEL WORKS, LTD.
    Inventor: Kengo Takeya
  • Publication number: 20020121355
    Abstract: The molten metal injector system includes a holder furnace, a casting mold supported above the holder furnace, and a molten metal injector supported from a bottom side of the mold. The holder furnace contains a supply of molten metal. The casting mold defines a mold cavity for receiving molten metal from the holder furnace. The injector projects downward into the holder furnace and is in fluid communication with the mold cavity. The injector includes a cylinder defining a piston cavity housing a reciprocating piston. The piston pumps molten metal upward from the holder furnace to the mold cavity. The cylinder further includes a molten metal intake for receiving molten metal into the piston cavity. The intake may be a valve or an aperture defined in the sidewall of the cylinder.
    Type: Application
    Filed: January 15, 2002
    Publication date: September 5, 2002
    Inventors: Nicolas Bigler, Guy Arnaud
  • Patent number: 6443215
    Abstract: A mold for casting a vehicle wheel includes a movable top core which cooperates with a base member to define a mold cavity. The mold also includes a plurality of movable segments mounted upon the top core. The movable segments define a central gate which communicates with the mold cavity. The central gate receives a charge of molten metal and feeds the charge into the mold cavity. A porous filter is disposed within the gate.
    Type: Grant
    Filed: December 29, 1999
    Date of Patent: September 3, 2002
    Assignee: Hayes Lemmerz International, Inc.
    Inventor: Douglas P. Mason
  • Publication number: 20020117288
    Abstract: A swing arm for actuating a magnetic head having a multiplicity of extremely thin blade of 0.9 mm in thickness that has been difficult to produce in a conventional casting may be produced by die-casting. Fixed cores and movable cores are disposed in a casting space provided in a parting line between a fixed core and a movable core. A body casting space and a blade casting space are set. A cross-sectional area of an overflow gate provided at an end of the blade casting space is greater than a cross-sectional area of a runner gate for connecting a runner and the body casting space. At the same time, a weight of the overflow material overflowed from the overflow gate to the molten material storage portion is set to be greater than a weight of a product portion filled in the casting space. The flow of the molten material to the blade casting space that is narrow is made smooth.
    Type: Application
    Filed: March 29, 2002
    Publication date: August 29, 2002
    Applicant: Minebea Co., Ltd.
    Inventors: Kazufusa Furukoshi, Takeaki Fuse, Naoto Miura
  • Patent number: 6435257
    Abstract: Fully dense long ingots are produced by the bottom pouring method and apparatus of the present invention. A solidification sequence is achieved which is conducive to eliminating solidification shrinkage and piping. The set-up of the bottom poured ingot molds facilitates a solidification sequence starting from the top and then down the ingot mold and then up the down pour pipe.
    Type: Grant
    Filed: March 15, 2001
    Date of Patent: August 20, 2002
    Assignee: Concurrent Technologies Corporation
    Inventor: Alex Simkovich
  • Publication number: 20020108737
    Abstract: A mould structure for producing metal castings by solidifying molten metal, in particular for producing a light-alloy engine crank-case, which includes a plurality of cores defining a mould cavity and a primary inlet aperture for feeding the molten metal into the bottom region of the mould cavity through the walls of one of the said cores, which includes: a metal containment structure, open at the top, with a bottom wall and side walls having a plurality of reference elements which have surface portions which complement surface portions of the said cores, the said cores being assembled inside the containment structure so that they are engaged with each other and with the said reference elements, and being shaped so as to define interstices between their surfaces facing outwardly of the mould cavity and the walls of the containment structure; and at least one cover element made of a highly heat-conductive material, supported by the side walls of the containment structure and by some of the said cores and servi
    Type: Application
    Filed: September 10, 2001
    Publication date: August 15, 2002
    Applicant: TEKSID S.p.A.
    Inventors: Gianni Crivellone, Sergio Gallo, Claudio Mus
  • Publication number: 20020104638
    Abstract: Apparatus for pouring of molten metal from a vessel onto the gating system of a mold includes a shield assembly that diverts any abnormal flow of molten metal occurring between normal flow of molten metal onto the gating system when molds are indexed for pouring. The shield assembly protects sensitive components of the mold, such as the gating and casting patterns in a lost foam casting process, from abnormal flow of molten metal.
    Type: Application
    Filed: September 20, 2001
    Publication date: August 8, 2002
    Inventors: Emad Tabatabaei, William R. Pflug
  • Publication number: 20020069997
    Abstract: An apparatus and process is provided for producing semi-solid material and directly casting the semi-solid material into a component wherein the semi-solid material is formed from a molten material and the molten material is introduced into a container. Semi-solid is produced therefrom by agitating, shearing, and thermally controlling the molten material. The semi-solid material is maintained in a substantially isothermal state within the container by appropriate thermal control and thorough three-dimensional mixing. Extending from the container is a means for removing the semi-solid material from the container, including a temperature control mechanism to control the temperature of the semi-solid material within the removing means.
    Type: Application
    Filed: February 19, 1999
    Publication date: June 13, 2002
    Inventors: PATRICIO F. MENDEZ, CHRISTOPHER S. RICE, STUART B. BROWN, SHINYA MYOJIN
  • Publication number: 20020046823
    Abstract: An improved method for forming cores to be utilized in a loss core plastic molding process includes the use of a flow meter. The flow meter ensures that sufficient molten metal is delivered into a cavity for the loss core elements. In this way, the present invention eliminates the occurrence of gaps, spaces or cavities in the molded loss core part. Most preferably a magnetic flow meter is utilized which can monitor the amount of molten metal having flown through the flow meter.
    Type: Application
    Filed: April 25, 2001
    Publication date: April 25, 2002
    Applicant: Siemens Automotive Corporation
    Inventor: Karthikeyan R. Narayanaswamy
  • Publication number: 20020036072
    Abstract: A casting process for casting, in particular of sand molds provided with casting boxes, which makes it possible to keep the apparatus expense low, to save cycle material and to achieve an improved quality, consists of the intake channel extending in a plane lying essentially horizontally during casting and being provided with a bearing surface defining its port, onto which bearing surface can be sealingly positioned a fill pipeline through which the mold can be filled with metal under low pressure. A casting system to carry out the method consists of a casting machine with a pressure kettle and a fill pipeline which is connected to the intake channel lying essentially in a horizontal plane, whereby the sealed coupling of fill pipeline and intake channel is obtained through specified bearing pressure.
    Type: Application
    Filed: November 2, 2001
    Publication date: March 28, 2002
    Applicant: Heinrich Wagner Sinto Maschinenfabrik GmbH
    Inventor: Herbert Grolla
  • Patent number: 6341640
    Abstract: In casting metal objects in casting cavities (2) in moulds (1), connectable to a pressurized mould-filling furnace (5) through a delivery tube (8) and a connector (9), an external riser (13) is connected to and extends upwardly from the junction of the tube (8) and the connector (9). The riser (13) is used as a temporary reservoir in which the level of molten metal is regulated by controlling the gas pressure in space 7 in the furnace (5) such that the filling head, defined as the difference in level between the metal in the casting cavities (2) and that in the external riser (13), is kept constant or made to vary in a desired manner, e.g. so as to cause the level in the cavities to ascend at a substantially constant rate. The invention makes it inter alia possible to produce high-quality aluminum castings in sand moulds, e.g. using automatic foundry equipment of the DISAMATIC® type.
    Type: Grant
    Filed: December 22, 1999
    Date of Patent: January 29, 2002
    Assignee: Georg Fischer Disa A/S
    Inventors: Peter Iversen, Uffe Andersen
  • Publication number: 20020000303
    Abstract: Production of light metal castings composed of magnesium or magnesium alloys, includes supplying a liquid metal first to a dosing chamber; pumping gas under pressure into the dosing chamber so as to press the liquid metal into a preliminarily evacuated mold nest; performing a production process within a system which is pressure-tightly closed from outside; performing heating of the liquid metal in a lower part of a melting device which adjoins a feed system; performing overheating of the liquid metal from a melting condition with a temperature of approximately 630° C. to a rigidification condition at a tool side to a lower region of a valve seat; and supplying and withdrawing a protective gas by a differential pressure system.
    Type: Application
    Filed: May 22, 2001
    Publication date: January 3, 2002
    Inventor: Bernhard Kern
  • Patent number: 6334478
    Abstract: In order to provide a die structure for injection molding of a light alloy free from gas defects, and a method of molding a light alloy parts using the die, the die structure is used for converting a light alloy into a semi-molten state, wherein a solid phase and a liquid phase coexist, or a molten state at a temperature just above a melting point and injecting the molten metal into an interior cavity portion, and S1/S2 of a gate sectional area S1 with respect to a maximum sectional area S2 of the cavity of the mold which area is almost perpendicular to the flowing direction of the melt therein is set in a range of 0.06 to 0.5.
    Type: Grant
    Filed: September 29, 1998
    Date of Patent: January 1, 2002
    Assignee: Mazda Motor Corporation
    Inventors: Kazuo Sakamoto, Kyoso Ishida, Yukio Yamamoto
  • Publication number: 20010037870
    Abstract: Fully dense long ingots are produced by the bottom pouring method and apparatus of the present invention. A solidification sequence is achieved which is conducive to eliminating solidification shrinkage and piping. The set-up of the bottom poured ingot molds facilitates a solidification sequence starting from the top and then down the ingot mold and then up the down pour pipe.
    Type: Application
    Filed: March 15, 2001
    Publication date: November 8, 2001
    Inventors: Kuang-O Yu, Alex Simkovich
  • Patent number: 6308768
    Abstract: An apparatus and process is provided for producing a semi-solid material suitable for directly casting into a component wherein the semi-solid material is formed from a molten material and the molten material is introduced into a container. Semi-solid is produced therefrom by agitating, shearing, and thermally controlling the molten material. The semi-solid material is maintained in a substantially isothermal state within the container by appropriate thermal control and thorough three dimensional mixing. Extending from the container is a means for removing the semi-solid material from the container, including a temperature control mechanism to control the temperature of the semi-solid material within the removing means.
    Type: Grant
    Filed: February 19, 1999
    Date of Patent: October 30, 2001
    Assignee: Semi-Solid Technologies, Inc.
    Inventors: Christopher S. Rice, Patricio F. Mendez, Stuart B. Brown, Shinya Myojin
  • Patent number: 6276437
    Abstract: Continuous casting machine for the casting of a thin slab with a thickness of less than 150 mm comprising a vacuum tundish having a first atmospheric chamber (7) and a second low pressure or vacuum chamber (1) hydraulically connected to the first chamber and purging means (11) for introducing a purging gas into the liquid steel after it has entered the first chamber but before it entered the second chamber.
    Type: Grant
    Filed: October 2, 1998
    Date of Patent: August 21, 2001
    Assignee: Corus Staal BV
    Inventor: Huibert Willem Den Hartog
  • Publication number: 20010013402
    Abstract: In order to provide a die structure for injection molding of a light alloy free from gas defects, and a method of molding a light alloy parts using the die, the die structure is used for converting a light alloy into a semi-molten state, wherein a solid phase and a liquid phase coexist, or a molten state at a temperature just above a melting point and injecting the molten metal into an interior cavity portion, and S1/S2 of a gate sectional area S1 with respect to a maximum sectional area S2 of the cavity of the mold which area is almost perpendicular to the flowing direction of the melt therein is set in a range of 0.06 to 0.5.
    Type: Application
    Filed: September 29, 1998
    Publication date: August 16, 2001
    Inventors: KAZUO SAKAMOTO, KYOSO ISHIDA, YUKIO YAMAMOTO
  • Patent number: 6250368
    Abstract: A mold is provided which is capable of producing a sound fiber-reinforced composite article utilizing a die-casting process. A cavity in the mold includes a composite article forming area in which a formed product of fiber is located, a molten metal storing area located adjacent the composite article forming area to fill a molten metal into the formed product of fiber, and a molten metal flow slackening area for reducing the turbulent flow of the molten metal from gates to introduce it to the molten metal storing area. Thus, the flow of the molten metal introduced into the molten metal storing area, is brought into a substantially laminar flow state, so that the inclusion of air in the molten metal flow is inhibited. Therefore, the molten metal in the molten metal storing area can be smoothly filled into the formed product of fiber under pressure.
    Type: Grant
    Filed: April 13, 1999
    Date of Patent: June 26, 2001
    Assignee: Honda Giken Kabushiki Kaisha
    Inventors: Hideaki Ushio, Kazuo Shibata, Kazuhisa Ishizuka
  • Patent number: 6244327
    Abstract: Disclosed is an integral single-cast multi wall structure including a very thin wall and a second thin wall. There is a passageway interposed between the pair of walls of the structure, and a high thermal conductivity member extends into said passageways and thermally couples the walls. The high thermal conductivity member increases the heat transfer between the walls of the structure. The present invention further includes a method for casting an integral structure having very thin walls that utilizes the high thermally conductive member in the casting process to hold the pattern and cores in alignment.
    Type: Grant
    Filed: December 8, 1998
    Date of Patent: June 12, 2001
    Assignee: Allison Engine Company, Inc.
    Inventor: Donald J. Frasier
  • Patent number: 6223806
    Abstract: A bottom casting apparatus comprises a pouring pipe, a stool, molds, and runners, wherein the runner satisfies the following equations (1) and (2) and a gap formed between a side wall of a groove for a runner provided in the stool and a runner brick is filled with heat resisting granules, A−D≦D(Z/100)+2.5 (mm)  (1) A−D>B−E>0  (2) where, A and B are widths (mm) at an upper portion and a bottom portion of the groove, respectively, D and E are widths (mm) at an upper portion and a bottom portion of the runner brick disposed within the groove, respectively, and Z is a mean coefficient of linear expansion (%) of the runner brick in the temperature range of a room temperature to 1000° C.
    Type: Grant
    Filed: April 5, 2000
    Date of Patent: May 1, 2001
    Inventors: Kazuhisa Nishino, Eiju Hayakawa
  • Patent number: 6199619
    Abstract: In an arrangement of an ingate system with feeding reservoir for feeding castings, preferably in moulds with pouring form the bottom (ascending casting), with which ingate system at least a feeding reservoir is connected. The ingate system is connected to one or a number of mould cavities least one feeding reservoir (7) is provided consituting a widened part of a duct (4) or a part of a duct in the ingate system (1), and that a partition (6) consisting of a gauze screen (6) or equivalent is provided separating the feeding reservoir (7) and the duct (4).
    Type: Grant
    Filed: October 28, 1998
    Date of Patent: March 13, 2001
    Assignee: Georg Fischer Disa A/S
    Inventor: Uffe Andersen
  • Patent number: 6196294
    Abstract: A casting plant for low-pressure casting of molten metal with operatively and kinematically connected units in the form of linear or revolving conveying devices.
    Type: Grant
    Filed: February 22, 1998
    Date of Patent: March 6, 2001
    Inventors: Gustav Ohnsmann, Gerold Bandt, Martin Ohnsmann
  • Patent number: 6192968
    Abstract: In a process for preparing the mold walls (12a, 12b) of a mold (12, 12) for the molding or shaping of a molded part after completion of the molding cycle and after removal of the molded part from the mold (12) to make the mold walls ready for the next molding cycle, the tempering of the mold walls (12a, 12b) and the coating of the walls with mold wall treatment agent are carried out independently of each other, i.e., without any time overlap, and in a controlled manner, preferably in a program-controlled manner. To apply the coating, preferably a spray element with centrifugal atomization and air control is used, the mold walls preferably being coated with essentially solvent-free mold wall treatment agent.
    Type: Grant
    Filed: September 23, 1998
    Date of Patent: February 27, 2001
    Assignee: Acheson Industries, Inc.
    Inventors: Hans-Dieter Renkl, Douwe Marten Kok, Thomas Junker, Karl-Heinz Keim
  • Patent number: 6138742
    Abstract: An apparatus for and method of pouring molten metal from a refractory vessel into the sprue of a mold where the vessel is in contact with the sprue. Molten metal is poured through the orifice of a nozzle in the bottom of the vessel. Laminar flow and velocity of the molten metal through the orifice are controlled by a stopper that extends from the orifice and also displaces molten metal in the sprue of the mold when the stopper is in the closed position to minimize excess buildup of solidified metal in the volume of the sprue. Filtering of dross can be accomplished in the refractory vessel and heating means can be provided to hold the molten metal at the appropriate temperature.
    Type: Grant
    Filed: December 16, 1998
    Date of Patent: October 31, 2000
    Assignee: Inductotherm Corp.
    Inventor: Montgomery W. Billau
  • Patent number: 6123142
    Abstract: Molten material is elevated into a mold cavity and subsequently pressure is brought to bear on the molten material in the mold cavity substantially immediately to solidify the molten material under pressure. The molten material is tapped from a reservoir of molten material below the surface of the molten material to minimize exposure to air of the molten material and transferred to the mold cavity without a downward flow or a pouring of the tapped molten material.
    Type: Grant
    Filed: November 28, 1997
    Date of Patent: September 26, 2000
    Assignee: Water Gremlin
    Inventor: Leon J. Ratte
  • Patent number: 6105658
    Abstract: In order to fill a casting mould with a molten metal, the latter is caused to flow into through an annular chamber into the shaped cavity of a casting mould, such annular chamber discharging over the entire external periphery of the shaped cavity into the latter. The inflow of molten metal into the annular chamber is interrupted by means of a piston, which, being borne inside the annular chamber, is capable of sliding therein. The molten metal can be caused to flow across a large flow cross-section, which shortens the filling time even with reduced flow velocity.
    Type: Grant
    Filed: June 15, 1998
    Date of Patent: August 22, 2000
    Assignee: BBS Kraftfahrzeugtechnik AG
    Inventor: Heinrich Baumgartner
  • Patent number: 6035922
    Abstract: To provide an apparatus for manufacturing a casting, in which sealing can be formed between joint surfaces of a mold without using any packing material. An apparatus for manufacturing a casting comprising a mold split into at least two mold parts designed so as to define a cavity, an introduction port provided at one end of the mold for introducing molten metal into the cavity, and an exhaust port provided at the other end of the mold for exhausting air in the cavity; characterized by further comprising a groove which is provided around a portion defining the cavity in at least one of joint surfaces of the at least two mold parts so as to connect the introduction port to the exhaust port.
    Type: Grant
    Filed: November 10, 1998
    Date of Patent: March 14, 2000
    Assignees: Sugitani Kinzoku Kogyo Kabushiki Kaisha, Toyo Aluminium Kabushiki Kaisha
    Inventors: Nobuhiro Sugitani, Shoichi Makimoto