Separation Of Unwanted Component From Melt Patents (Class 164/134)
  • Patent number: 10780476
    Abstract: A method for making Mg brass EDM wire has the steps of melting a charge of Mg brass to form a melt of Mg brass; transferring the melt to a holding furnace; casting a rod from the melt; and drawing the rod down to a size suitable for EDM machining. Mg deposits may form in the holding furnace. These can be removed by flushing the holding furnace with molten brass.
    Type: Grant
    Filed: February 14, 2019
    Date of Patent: September 22, 2020
    Assignee: E. Holdings, Inc
    Inventors: David Joseph Dudas, Richard Balon
  • Patent number: 10352620
    Abstract: A system for transferring molten metal from a vessel and into one or more of a ladle, ingot mold, launder, feed die cast machine or other structure is disclosed. The system includes at least a vessel for containing molten metal, an overflow (or dividing) wall, and a device or structure, such as a molten metal pump, for generating a stream of molten metal. The dividing wall divides the vessel into a first chamber and a second chamber, wherein part of the second chamber has a height H2. The device for generating a stream of molten metal, which is preferably a molten metal pump, is preferably positioned in the first chamber. When the device operates, it generates a stream of molten metal from the first chamber and into the second chamber. When the level of molten metal in the second chamber exceeds H2, molten metal flows out of the vessel and into another structure, such as into one or more ladles and/or one or more launders.
    Type: Grant
    Filed: June 22, 2015
    Date of Patent: July 16, 2019
    Assignee: Molten Metal Equipment Innovations, LLC
    Inventor: Paul V. Cooper
  • Patent number: 9850969
    Abstract: A method of forming a rotor by forming a mold by forming a first mold cake, a second mold cake, and a core that fits between the first and the second mold cake. The method includes a step of locating the core between the first mold cake and the second mold cake. The core includes a body, one or more projections extending from the body for forming one or more holes in a base portion of the rotor, and one or more projections extending from the body for forming one or more holes in a bat wall of the rotor.
    Type: Grant
    Filed: June 9, 2015
    Date of Patent: December 26, 2017
    Assignee: AKEBONO BRAKE INDUSTRY CO., LTD.
    Inventors: Eric J. Barber, Brian C. Nadeau
  • Patent number: 9770754
    Abstract: A device and method for transferring filtered molten metal to a die casting mold. The device and method include a casting filtration system that includes a funnel and a continuously replaceable filter placed fluidly between a molten metal source and a casting mold. Both the funnel and filter are automatically moved into cooperation with a molten metal receptacle such as a shot sleeve prior to each casting operation, and then automatically moved out of the way so that pressurization of the filtered molten metal may take place in the receptacle. In addition, the filter may be formed on a continuous strand such that indexed movement of the strand will advance the used portion of the filter out of the way to make room for a new unused filter portion that will be ready for a subsequent repeated casting operation.
    Type: Grant
    Filed: March 27, 2015
    Date of Patent: September 26, 2017
    Assignee: GM GLOBAL TECHNOLOGY OPERATIONS LLC
    Inventors: David D. Goettsch, Jason R. Traub, Michael J. Walker, Brad A. Ohlrich
  • Patent number: 9694417
    Abstract: A pivotable tundish (1) for continuous casting a metal alloy. The tundish includes a body (3) with a first chamber (5), a second chamber (7), a first passage (12) between the first chamber and the second chamber, and a second passage (16) between the second chamber and a mold (9). The first chamber is adapted to receive and hold a base metal constituting the base for forming the metal alloy by addition of alloying elements. The metal alloy is fed from the second chamber to the mold through the second passage. The second chamber further includes a first portion (30) and a second portion (32), and a third passage (36) between the first portion and the second portion. In the casting state the metal alloy is formed while casting by adding the alloying elements to the second portion of the second chamber.
    Type: Grant
    Filed: February 10, 2012
    Date of Patent: July 4, 2017
    Inventor: Sarita Hernesniemi
  • Patent number: 9676029
    Abstract: A pour tube for casting molten metal is adapted to reduce turbulence and mold disturbances, thereby producing a more stable, uniform outflow. The pour tube has a central longitudinal axis and includes a bore in communication with a port distributor having a greater radius with respect to the longitudinal axis than does the bore. Exit ports provide fluid communication between the port distributor and the exterior of the device. Each of a pair of larger exit ports has a larger cross-sectional area than does either of a pair of smaller exit ports.
    Type: Grant
    Filed: August 7, 2015
    Date of Patent: June 13, 2017
    Assignee: VESUVIUS CRUCIBLE COMPANY
    Inventor: Johan L. Richaud
  • Patent number: 8939193
    Abstract: Method and apparatus for flowing molten metal substantially vertically into a mold by means of a feeder tube while concurrently impeding the flow of oxides that collect at the perimeter of the head of the feeder tube. This reduces inclusions in the molten metal and improves the quality of a molded component as the molten metal solidifies.
    Type: Grant
    Filed: August 22, 2007
    Date of Patent: January 27, 2015
    Inventors: Peio Todorov Stoyanov, Ching-Lung Wang
  • Patent number: 8794298
    Abstract: One embodiment of the present invention is a unique filter and a method for manufacturing the same. Another embodiment is a unique system for casting a metallic object. Another embodiment is a unique method of filtering a molten metal. Other embodiments include apparatuses, systems, devices, hardware, methods, and combinations for filtering molten metal. Further embodiments, forms, features, aspects, benefits, and advantages of the present application shall become apparent from the description and figures provided herewith.
    Type: Grant
    Filed: December 28, 2010
    Date of Patent: August 5, 2014
    Assignee: Rolls-Royce Corporation
    Inventors: Max Eric Schlienger, Paul Anthony Withey, Michael Christopher Maguire, Michael Dean Baldwin
  • Patent number: 8627874
    Abstract: A mold for casting metal which allows solid impurities to be removed from the molten metal. The mold (50) has a cavity therein, said cavity having a casting portion and contiguous therewith a running system upstream of the casting portion, said running system comprising an upstream inlet portion (58), a downstream outlet portion (60) and a swirl chamber (54) disposed between the inlet and outlet portions (58, 60), wherein a filter (62) is provided at an interface between the swirl chamber (54) and the outlet portion (60). The application also relates to a method for preparing the mold, a pattern for preparing the mold, a housing for use in the mold and a method for casting employing the mold.
    Type: Grant
    Filed: May 25, 2012
    Date of Patent: January 14, 2014
    Assignee: Foseco International Limited
    Inventors: Petr Filip, David Hrabina, Mairtin Burns
  • Patent number: 8622114
    Abstract: A molded article includes a flat plate portion and a projected portion. A molding method includes filling a cavity with the semimolten or semisolid metal in plate thickness directions of the flat plate portion starting from a surface on an opposite side of the flat plate portion from the surface from which the projected portion projects. The cavity is a casting space of the molded article formed inside a forming mold. A molding apparatus for casting the molded article includes a forming mold having the cavity, and a separate insert or slide mold disposed between the cavity and a runner in order to form the runner in plate thickness directions of the flat plate portion starting from the other surface. The runner is used to fill the cavity.
    Type: Grant
    Filed: June 23, 2009
    Date of Patent: January 7, 2014
    Assignees: Daikin Industries, Ltd., Kogi Corporation
    Inventors: Mitsuhiko Kishikawa, Masateru Yamamoto, Satoshi Yamamoto, Toshio Ohkado, Jun Iwane, Shuichi Shikai
  • Publication number: 20130068413
    Abstract: Method and apparatus for flowing molten metal substantially vertically into a mold by means of a feeder tube while concurrently impeding the flow of oxides that collect at the perimeter of the head of the feeder tube. This reduces inclusions in the molten metal and improves the quality of a molded component as the molten metal solidifies.
    Type: Application
    Filed: August 22, 2007
    Publication date: March 21, 2013
    Inventors: Peio Todorov Stoyanov, Ching-Lung Wang
  • Patent number: 8327915
    Abstract: A casting apparatus and a method of forming a casting using the casting apparatus is disclosed, the casting apparatus comprising a ladle having a hollow interior adapted to receive a molten material therein; a nozzle in fluid communication with the hollow interior, the nozzle having a first portion disposed outside of the ladle and a second portion disposed within the hollow interio; an additive feeder in fluid communication with the hollow interior of the ladle; and a gas conduit in fluid communication with the hollow interior of the ladle.
    Type: Grant
    Filed: May 25, 2011
    Date of Patent: December 11, 2012
    Assignee: GM Global Technology Operations LLC
    Inventors: Christopher D. Cogan, Stephen M. Fitch, Qigui Wang
  • Publication number: 20120138255
    Abstract: The present invention arranges the part for removing impurities from a molten metal containing a filter holder constituted of a structure containing an organic fiber, an inorganic fiber and thermosetting resin and a heat-resistant filter in the runner of the mold.
    Type: Application
    Filed: December 7, 2011
    Publication date: June 7, 2012
    Inventors: Shigeaki TAKASHINA, Tokuo TSUURA, Tomoaki KAWABATA, Daisuke BARADA
  • Patent number: 8186420
    Abstract: A mould for casting metal which allows solid impurities to be removed from the molten metal. The mould (50) has a cavity therein, said cavity having a casting portion and contiguous therewith a running system upstream of the casting portion, said running system comprising an upstream inlet portion (58), a downstream outlet portion (60) and a swirl chamber (54) disposed between the inlet and outlet portions (58,60), wherein a filter (62) is provided at an interface between the swirl chamber (54) and the outlet portion (60). The application also relates to a method for preparing the mould, a pattern for preparing the mould, a housing for use in the mould and a method for casting employing the mould.
    Type: Grant
    Filed: November 19, 2009
    Date of Patent: May 29, 2012
    Assignee: Foseco International Limited
    Inventors: Petr Filip, David Hrabina, Mairtin Burns
  • Patent number: 8096346
    Abstract: A method of casting a base of high-power wind turbines with low-temperature nodular graphite iron, using furan resin sand as the mold sand and having no risers or chills in the mold. The mold undergoes microseismic compaction and has no chills risers. The parting face of the mold is perpendicular to the ground. The molten iron in the mold is solidified evenly. Therefore, shrinkage holes and disperse shrinkages base are reduced greatly and the dregs and air are discharged easily for the base. The pouring system designed together with a reasonable pouring rate and time make the filtering system useful for blocking dregs.
    Type: Grant
    Filed: February 1, 2009
    Date of Patent: January 17, 2012
    Assignee: Jiangsu Jixin Wind Energy Technology Co., Ltd.
    Inventors: Yongluo Hua, Jianhong Wang, Yufang Chen, Qiang Wang, Yuebing Wu
  • Patent number: 7967053
    Abstract: This invention relates to filters made from a refractory material, preferably an insulating material, and chemical binder. The filters are used in the foundry industry to filter molten metal. The invention also relates to a process for preparing the filters.
    Type: Grant
    Filed: September 29, 2009
    Date of Patent: June 28, 2011
    Assignee: ASK Chemicals L.P.
    Inventors: Ronald C. Aufderheide, Ralph E. Showman
  • Patent number: 7955414
    Abstract: A method and device for the purification and separation of purified metal from a metal mother liquid having a specific density and comprising one or more foreign element(s). The method includes: providing in a column device a starting material including metal crystals and a metal mother liquid including at least one foreign element; applying a temperature difference between a relatively hot zone at the upper end of the column and a relatively cool zone at the lower end of the column; a separation step wherein at least a part of the metal crystals is separated from the metal mother liquid by rising of the metal crystals to the upper surface of the metal mother liquid; and a further separation step wherein purified metal floating on the upper surface of the metal mother liquid is discharged from the column device.
    Type: Grant
    Filed: July 5, 2007
    Date of Patent: June 7, 2011
    Assignee: Aleris Switzerland GmbH
    Inventors: Huibrecht Adriaan Wouters, Andreas Ten Cate, Elisabeth Maria Beunder, Willem Boender, Marcellus Albertus Hogenboom, René Kieft, Joost Christiaan Storm
  • Patent number: 7712514
    Abstract: Methods for reducing inclusion content of sputter targets and targets so produced are disclosed. Inclusions may be reduced by adding a small amount of Si to the molten Al or molten Al alloy followed by filtering of the molten metals through a filter medium. Targets having substantially no inclusions therein of greater than about 400 ?m are especially useful in the sputtering of large flat panel displays and result, upon sputtering, in a reduction in the amount of macroparticles sputtered onto the substrate.
    Type: Grant
    Filed: December 1, 2008
    Date of Patent: May 11, 2010
    Assignee: Tosoh SMD, Inc.
    Inventors: Charles E. Wickersham, Jr., John E. Poole, Alexander Leybovich, Lin Zhu
  • Publication number: 20100096099
    Abstract: The present invention arranges the part for removing impurities from a molten metal containing a filter holder constituted of a structure containing an organic fiber, an inorganic fiber and thermosetting resin and a heat-resistant filter in the runner of the mold.
    Type: Application
    Filed: December 12, 2007
    Publication date: April 22, 2010
    Applicant: Kao Corporation
    Inventors: Shigeaki Takashina, Tokuo Tsuura, Tomoaki Kawabata, Daisuke Barada
  • Patent number: 7578336
    Abstract: A casting mold and method for its use to achieve in-mold modification of the casting metal is disclosed. One or more chambers are located within the casting mold's runner system. Each chamber can contain metallurgical modifiers for adjusting the chemical composition of the metal to improve the mechanical and physical properties of an article cast from the metal. One or more modifiers can be placed in the chamber(s) as the casting mold is assembled for use. As the melt is introduced to the casting mold, it passes through the chamber(s) and liquefies the modifier. Amounts of the liquid modifier, then, are carried away and become dispersed in the melt as it continues through the runner system and into the mold cavity. The metallurgical modifiers can be selected from any number of known additives or alloying elements, including strontium, among others.
    Type: Grant
    Filed: June 13, 2007
    Date of Patent: August 25, 2009
    Inventors: Kenneth George Stahl, Jr., Venkatramanan Srinivasan, James T. Singer, Edward C. Wall, Mark A. Osborne
  • Publication number: 20090078391
    Abstract: Methods for reducing inclusion content of sputter targets and targets so produced are disclosed. Inclusions may be reduced by adding a small amount of Si to the molten Al or molten Al alloy followed by filtering of the molten metals through a filter medium. Targets having substantially no inclusions therein of greater than about 400 ?m are especially useful in the sputtering of large flat panel displays and result, upon sputtering, in a reduction in the amount of macroparticles sputtered onto the substrate.
    Type: Application
    Filed: December 1, 2008
    Publication date: March 26, 2009
    Applicant: Tosoh SMD, Inc.
    Inventors: Charles E. Wickersham, JR., John E. Poole, Alexander Leybovich, Lin Zhu
  • Patent number: 7431069
    Abstract: A technique for pressurized or differential pressure casting according to the present disclosure provides a riser tube filter formed of ceramic foam having a specific gravity lower than the molten metal to be cast. A riser tube filter according to the present invention may float in and/or on the molten metal within the riser tube and smooth the flow of molten metal within the riser tube simultaneously filtering the metal. As the molten metal is depressurized, a riser tube filter according to the present disclosure will travel back down the riser tube engaging the walls of the riser tube and minimizing the surface of molten metal in contact with the air or other gas. It is emphasized that this abstract is provided to comply with the rules requiring an abstract that will allow a searcher or other reader to quickly ascertain the subject matter of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims.
    Type: Grant
    Filed: January 6, 2005
    Date of Patent: October 7, 2008
    Inventor: Fu Shun Liang
  • Patent number: 7353858
    Abstract: Disclosed is: (i) a cap for servicing a molding-system valve, and (ii) a method of a cap for servicing a molding-system valve, amongst other things.
    Type: Grant
    Filed: May 17, 2006
    Date of Patent: April 8, 2008
    Assignee: Husky Injection Molding Systems Ltd.
    Inventor: Jan Marius Manda
  • Publication number: 20080073053
    Abstract: A device and method for improved production of steel and other metals. The device and method captures sand or other insulating material used in the handling of molten metals and prevents or minimizes contamination of finished or intermediate metal products with said sand or other insulating material.
    Type: Application
    Filed: September 22, 2006
    Publication date: March 27, 2008
    Inventors: James Michael Shepherd, Rickey G. Crandall, John Carl Holderfield
  • Patent number: 7011133
    Abstract: A filter material for molten aluminum, the material subsequently dissolvable in molten aluminum to recover aluminum captured therein.
    Type: Grant
    Filed: February 2, 2004
    Date of Patent: March 14, 2006
    Inventor: C. Edward Eckert
  • Patent number: 6986380
    Abstract: Intervening fingers mounted within a mold gate cavity extend across a portion of the gate cavity and cooperate with one another to slow the flow of molten metal into the mold cavity and thereby reduce flow turbulence.
    Type: Grant
    Filed: July 30, 2004
    Date of Patent: January 17, 2006
    Assignee: Hayes Lemmerz International, Inc.
    Inventors: Steve Rice, Tim O'Banion
  • Patent number: 6913063
    Abstract: A dispensing arrangement for inserting a part into a cast iron mold includes a dispenser apparatus configured to dispense a predetermined number of parts, a staging apparatus configured to position the parts in a selective orientation and a jig apparatus configured to grip and lift the parts from the staging apparatus and position the parts in a die of a mold. The apparatus may be located adjacent the mold in use.
    Type: Grant
    Filed: April 2, 2003
    Date of Patent: July 5, 2005
    Assignee: Toyota Motor Manufacturing North America, Inc.
    Inventor: Christopher E. Ulerick
  • Patent number: 6860315
    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: Grant
    Filed: July 26, 2001
    Date of Patent: March 1, 2005
    Assignee: Copeland Corporation
    Inventor: Warren G. Williamson
  • Publication number: 20040238152
    Abstract: The present invention of a gating system comprises the use of modular gating system consisting of one or more filtering media flanked on at least one side by an evaporative foam layer, which is left inside the mold. The modular gating system permits the entry of metal to any surface of the mold without going through the parting line of the pattern.
    Type: Application
    Filed: May 26, 2004
    Publication date: December 2, 2004
    Inventors: Edgardo Campomanes, Patrick Campomanes
  • Publication number: 20040194905
    Abstract: A dispensing arrangement for inserting a part into a cast iron mold includes a dispenser apparatus configured to dispense a predetermined number of parts, a staging apparatus configured to position the parts in a selective orientation and a jig apparatus configured to grip and lift the parts from the staging apparatus and position the parts in a die of a mold. The apparatus of the present invention may be located adjacent the mold in use.
    Type: Application
    Filed: April 2, 2003
    Publication date: October 7, 2004
    Inventor: Christopher E. Ulerick
  • Publication number: 20040123970
    Abstract: An apparatus for filtering molten metal held in a vessel before the metal enters the dosing tube. The filtering apparatus includes an attachment portion that mounts to the dosing tube, a filter body connected to the attachment portion and a planar surface attached to an end of the filter body opposite the attachment portion. The filter body can include a beveled end opposite the attachment portion where the planar surface is attached. The apparatus can be made from a bonded-particle material made from silicon carbide or aluminum oxide held together by an aluminum-resistant binder.
    Type: Application
    Filed: September 11, 2003
    Publication date: July 1, 2004
    Applicant: Metaullics Systems Co. L.P.
    Inventor: David Neff
  • Publication number: 20040112563
    Abstract: A casting receptable for processing melt. The receptable comprises a lid, a shell, the bottom part of which is in the shape of a downwards convergent cut cone, a filling opening at the bottom of the casting receptable, and further a shutter plug that is movable in the vertical direction by means of an actuator and arranged to close and open the filling opening to allow melt to enter and correspondingly exit the casting receptable. The bottom end of the shutter plug is a sharp cone in shape, and the bottom end of the shutter plug extends in its closed position a distance further than the conical part of the shell, thus forming a sharp point at the bottom of the casting receptable. Further, the invention relates to a casting method that utilizes the casting receptable of the invention.
    Type: Application
    Filed: November 20, 2003
    Publication date: June 17, 2004
    Inventors: Markku Eljaala, Jarkko Laine, Arto Muikku
  • Patent number: 6648058
    Abstract: A modular casting system includes a plurality of casting modules and, is provided with on-board systems such as a lubrication system, cooling system, etc., which operate independently from similar systems on other modules of the system. Each of the casting modules is connected by quick disconnect connections to a centrally disposed source of fluid pressure and electrical power and a control unit for controlling each of the modules independently. Each of the modules is readily removable from the system and replaced with a new module of a different type or with a different mold. Each of the modules is preferably provided with a filter removal unit which is operative to raise the filter during the cooling operation and facilitates removal of the filter upon completion of the pouring operation. The upper platen of a casting module is provided with a swinging cope which is movable between a horizontal position and a vertical position to facilitate cleaning of the cope.
    Type: Grant
    Filed: June 11, 2002
    Date of Patent: November 18, 2003
    Inventors: Robert L. Macheske, Kenneth D. McKibben, Daniel D. Minor, Rick A. Van Horn
  • 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: 6585797
    Abstract: The melter furnace includes a heating chamber (16), a pump chamber (18), a degassing chamber (20), and a filter chamber (22). The pump chamber (18) is located adjacent the heating chamber (16) and houses a molten metal pump (30). The degassing chamber (20) is located adjacent and in fluid communication with the pump chamber (18), and houses a degassing mechanism (36). The filter chamber (22) is located adjacent and in fluid communication with the degassing chamber (20). The filter chamber (22) includes a molten metal filter (38). The melter furnace (12) is used to supply molten metal to an externally located holder furnace (14), which then recirculates molten metal back to the melter furnace (12).
    Type: Grant
    Filed: January 24, 2002
    Date of Patent: July 1, 2003
    Assignee: Alcoa Inc.
    Inventors: Michael J. Kinosz, Thomas N. Meyer
  • Patent number: 6578620
    Abstract: The filtering molten metal injector system includes a holder furnace, a casting mold supported above the holder furnace, and at least one molten metal injector supported from a bottom side of the casting mold. The holder furnace contains a supply of molten metal. The mold defines a mold cavity for receiving the molten metal from the holder furnace. The molten metal injector projects into the holder furnace. The molten metal injector includes a cylinder defining a piston cavity housing a reciprocating piston for pumping the molten metal upward from the holder furnace to the mold cavity. The cylinder and piston are at least partially submerged in the molten metal when the holder furnace contains the molten metal. The cylinder or the piston includes a molten metal intake for receiving the molten metal into the piston cavity when the holder furnace contains molten metal. A conduit connects the piston cavity to the mold cavity.
    Type: Grant
    Filed: November 9, 2000
    Date of Patent: June 17, 2003
    Assignee: Alcoa Inc.
    Inventors: David R. Trudel, Thomas N. Meyer, Michael J. Kinosz, Guy Arnaud, Nicolas Bigler
  • Patent number: 6540005
    Abstract: A recess (2) forming a pouring gate (2) is provided in a first half (1a) of the mold (1) so as to open out in the parting face (4) in a housing (5) having a top opening (6) in its top portion. A second recess (8) is provided in the second half (1b) of the mold (1) with an opening (9) in the parting face (4) of dimensions smaller than the corresponding dimensions of the housing. The two mold halves (1a, 1b) are assembled together on the parting face (4) and a filter (12) adapted to filter molten metal is inserted into the housing (5) substantially vertically through the top opening (6) thereof.
    Type: Grant
    Filed: February 9, 2001
    Date of Patent: April 1, 2003
    Assignee: Daussan & Compagnie
    Inventors: Jean Daussan, Gérard Daussan, André Daussan
  • 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
  • Publication number: 20020129919
    Abstract: A filter assembly for filtering molten metal poured into a mold includes a filter formed from refractory material, the filter having first and second porous surfaces through which molten metal may flow, and a peripheral surface and a locator attachable to at least one of the first, second and peripheral surfaces of the filter and arranged to extend from the at least one of the first, second and peripheral surfaces of the filter to another of the first, second and peripheral surfaces or to another part of those surface(s), during use. The locator locates the filter in a mold into which molten metal is poured.
    Type: Application
    Filed: May 1, 2002
    Publication date: September 19, 2002
    Applicant: FOSECO INTERNATIONAL LIMITED.
    Inventors: Philip Sandford, Richard B. Williams, Brian E. Began
  • Patent number: 6451246
    Abstract: A molten metal vessel includes a first chamber for containing molten metal such as molten aluminum therein, a filtration chamber in which impurities contained in the molten metal are removed, and a second chamber for reserving clean molten metal to be supplied to a casting die. The molten metal flows from the first chamber to the second chamber through the filtration chamber. A pair of filters, preferably a pair of cylindrical filters, are disposed in the filtration chamber, so that the impurities contained in the molten metal can be filtered twice. The filters are attached to the bottom of the filtration chamber where molten metal oxides hardly develop, so that the filters are easily replaced with new ones for the maintenance purpose. A rod-shaped heater may be disposed in the cylindrical filters to keep the molten metal temperature in a strictly controlled range. Thus, the impurities are effectively removed from the molten metal through the filters which are easily replaceable.
    Type: Grant
    Filed: April 24, 2001
    Date of Patent: September 17, 2002
    Assignee: Denso Corporation
    Inventors: Tomoyuki Hatano, Takeshi Nagasaka, Hiromi Takagi, Sumi Yoshikawa, Shunji Moohizuki
  • 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: 20010035277
    Abstract: A modular casting system includes a plurality of casting modules and, is provided with on-board systems such as a lubrication system, cooling system, etc., which operate independently from similar systems on other modules of the system. Each of the casting modules is connected by quick disconnect connections to a centrally disposed source of fluid pressure and electrical power and a control unit for controlling each of the modules independently. Each of the modules is readily removable from the system and replaced with a new module of a different type or with a different mold. Each of the modules is preferably provided with a filter removal unit which is operative to raise of the filter during the cooling operation and facilities removal of the filter upon completion of the pouring operation. The casting modules are provided with a tilting launder tray which facilitates laundering of the mold after a casting operation.
    Type: Application
    Filed: May 9, 2001
    Publication date: November 1, 2001
    Inventors: Robert L. Macheske, Kenneth D. McKibben, Daniel D. Minor, Rick A. Van Horn
  • Patent number: 6290900
    Abstract: A molten metal vessel includes a first chamber for containing molten metal such as molten aluminum therein, a filtration chamber in which impurities contained in the molten metal are removed, and a second chamber for reserving clean molten metal to be supplied to a casting die. The molten metal flows from the first chamber to the second chamber through the filtration chamber. A pair of filters, preferably a pair of cylindrical filters, are disposed in the filtration chamber, so that the impurities contained in the molten metal can be filtered twice. The filters are attached to the bottom of the filtration chamber where molten metal oxides hardly develop, so that the filters are easily replaced with new ones for the maintenance purpose. A rod-shaped heater may be disposed in the cylindrical filters to keep the molten metal temperature in a strictly controlled range. Thus, the impurities are effectively removed from the molten metal through the filters which are easily replaceable.
    Type: Grant
    Filed: March 11, 1999
    Date of Patent: September 18, 2001
    Assignee: Denso Corporation
    Inventors: Tomoyuki Hatano, Takeshi Nagasaka, Hiromi Takagi, Sumi Yoshikawa, Shunji Mochizuki
  • Patent number: 6289969
    Abstract: A filter unit for use in metal casting including a filter adapter, a filter adapter per se, and a mold for use in metal casting utilizing the filter unit, as well as a method of producing a metal casting, facilitate or practice direct pouring in a manner which provides for greater flexibility, being applicable to a wider range of castings. The apparatus elements and method are particularly suitable for the manufacturing of castings of relatively high modulus and low pour weight, and for the manufacture of high volume castings of low modulus. The mold includes a mold cavity and a sprue, a filter unit located in the sprue, and the filter unit comprising an adapter of refractory material having one or more ledges o10 for mounting a filter, and a filter (e.g. ceramic foam filter) supported by one of the ledges.
    Type: Grant
    Filed: March 31, 1999
    Date of Patent: September 18, 2001
    Assignee: Foseco International Limited
    Inventors: John F. Outten, Robert S. Sisetski
  • 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: 6019158
    Abstract: A ceramic investment mold is disposed in a casting chamber and communicates with a pour cup 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 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 reservoir pressurization. While residing in the pour cup 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: May 14, 1998
    Date of Patent: February 1, 2000
    Assignee: Howmet Research Corporation
    Inventors: Mark L. Soderstrom, Dale A. Grumm, Lester G. Striker
  • Patent number: 5954116
    Abstract: A shot sleeve for a die casting machine includes an elongated hollow body for receiving and guiding a shot plunger. This body defines an elongated chamber of predetermined cross-section having a front opening leading to a sprue runner of a die. The cross-section enlarges over part of its length towards the front opening. The plunger's front surface can include a conical surface which tapers away from a perimetrical scraping edge of the plunger, the conical surface having an axial end surface of smaller cross-section than the perimetrical edge. The arrangement allows undesirable material such as scrape peripheral portions of a slug of semi-solid metal to be trapped in a biscuit which remains in the shot sleeve after formation of a part.
    Type: Grant
    Filed: August 22, 1997
    Date of Patent: September 21, 1999
    Assignee: Buhler AG
    Inventor: Paul Jung
  • Patent number: 5914440
    Abstract: The present invention is concerned with a system for the filtration of molten material. The system is particularly useful for removing MgO impurities present in molten magnesium chloride electrolyte. The invention also comprises a method for removing solid particles from molten materials. Preferred molten materials include magnesium, aluminum, magnesium chloride electrolyte and aluminum electrolyte. The concentration of solid remaining in the molten material is less than 0.05 wt %.
    Type: Grant
    Filed: March 18, 1997
    Date of Patent: June 22, 1999
    Assignee: Noranda Inc.
    Inventors: Cesur Celik, Pasquale Ficara, Daniel Laroche
  • Patent number: 5908065
    Abstract: Squeeze casting of high integrity, near net shape castings is performed in a mould cavity defined by cooperating die parts which are movable with respect to each other and have a separation distance which is selected to define a predetermined cavity volume for the cast article. A conduit has a first end connected to an entrance in the lower die part of the mould cavity and a second end connected to a receptacle which contains molten metal. Molten metal is transferred upwardly from the receptacle through the conduit to fill or substantially fill the mould cavity. The entrance to the mould cavity is sealed, and pressure is applied on the die parts to further reduce the cavity volume during solidification of the metal in the mould cavity.
    Type: Grant
    Filed: September 26, 1997
    Date of Patent: June 1, 1999
    Assignee: Papervision Limited
    Inventor: Geoffrey Allan Chadwick
  • Patent number: RE41824
    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: September 14, 2005
    Date of Patent: October 19, 2010
    Assignee: Pleiatech Corporation
    Inventor: Akira Takayanagi