Abstract: A method of forming prototype metal castings by forming and modifying one or more sand mold elements of a sand mold assembly. The method includes molding and patterning sand into shapes of the sand mold elements and then forming a first metal casting by filling the internal cavity of the first sand mold assembly with molten metal material. The first metal casting is evaluated for strength or other desirable characteristics. Once a defect is noted the sand mold elements are modified by machining sand away from at least one of the sand mold elements of a later formed sand mold assembly to modify the shape of the internal cavity between mold elements. Machining modifications are determined from evaluating the first metal casting. Then a modified metal casting is made by filling the modified internal cavity of the modified sand mold assembly with molten metal material.

Abstract: A die-clamping system has a die and a clamping means. The die includes a first engaging portion in a first predetermined shape. The die is transferred in a first direction from a first position toward a second position. The clamping means has a second engaging portion in a second predetermined shape that is complementary to the first predetermined shape. The second engaging portion of the clamping means at the second position completes engagement with the first engaging portion by the time when the die arrives at the second position in the first direction.

Abstract: The invention relates to a casting method for producing a box piston which comprises recesses between the hub support and the ring band. The invention aims to further reduce the weight of the piston. The casting cores which produce the recesses can therefore be pivoted during stripping.

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.

Abstract: A die-casting system includes a core withdrawing device (50). The core withdrawing device is configured independently of a die (D1, D2) and is operable to withdraw a core (d) from the die.

Abstract: Die opening apparatus (50) of a die-casting system (10) is operable to open a die (D1, D2). A first cylinder (51) may perform an initial die opening operation and a second cylinder (55) may perform a subsequent die opening operation. The thrust generated by the first cylinder is preferably directly transmitted to the die in a die opening direction, optionally via a push pin (52).

Abstract: An engine block mold package is assembled from resin-bonded sand cores in a manner that reduces contamination of the engine block cast in the mold package by loose sand abraded off the cores during assembly. An assembly of multiple cores (core package) of the engine block mold package is formed apart from a base core. The core package is cleaned to remove loose sand therefrom. The cleaned core package then is positioned on the base core followed by assembly of a cover core to complete the engine block mold package for casting of an engine block therein.

Abstract: The invention relates to a device and a method for producing a blade (13; 14) comprising two outer walls (17, 18) and at least one cavity (24; 25; 26; 27) between said outer walls (17, 18), for a turbine (10), using an outer mould (30) and several cores (34, 35) for forming the outer walls (17, 18) and the at least one cavity (24; 25; 26; 27) of the blade (13, 14). At least one of the cavities (26; 27) is divided into two channels (26a, 26b; 27a, 27b) by a middle segment (28). One channel (26a; 27a) is located between the first outer wall (17) and the middle segment (28), while the other channel (26b; 27b) is located between the middle segment (28) and the second outer wall (18). Two cores (34, 35) which are separate from each other are used accordingly. This provides a simple and economical means of reducing the thickness (d) of the outer walls (17, 18).

Abstract: The invention relates to a device for manufacturing a metallic hollow body (1) having at least one hollow space (3, 5, 17) and a wall encompassing the hollow space, comprising an exterior casting mold which has at least one inside core (33, 35, 47) serving to form the hollow space. The exterior casting mold is separable into at least two exterior members (29A, 29B) and the inside core (33, 35, 47) is connected via at least one connecting element (53), which serves to form a through-opening (25) in the wall (23) into the hollow space (3, 5, 7), with an exterior member (29A, 29B) of the exterior casting mold.

Abstract: An engine block mold package is assembled from resin-bonded sand cores in a manner that reduces parting lines on the exterior surfaces of the mold package. An assembly of multiple cores (core package) is formed and includes multiple inter-core parting lines extending in different directions on exterior surfaces of the core assembly. The core package is disposed between a base core and a cover core configured to enclose the core package and form a single continuous exterior parting line about the assembled mold package.

Abstract: In assembly of engine block mold package, a water jacket slab core is assembled on a barrel crankcase core having a plurality of barrels on which cylinder bore liners are positioned. Some of the barrels include a core print on a distal end thereof. The water jacket slab core includes a plurality of core prints each in mating relation with a respective barrel core print and a plurality of bore liner positioning surfaces that each engage a respective distal end of a respective cylinder bore liner when the water jacket slab core is assembled on the barrels.

Abstract: A die casting machine has a divisible die casting tool. To be able to die cast in a secure manner large die-cast parts beyond elasticity-caused limits of the machine construction, the locking pressures for the die casting tool are transmitted by tool-integrated tie rods into a power flux circuit remaining within the die casting tool. In the closed condition of the die casting tool, the tie rods can be anchored in a tension proof manner on both sides of its mold parting surface in the die casting tool and, for the opening, can be detached at least from one of the tool parts of the die casting tool. For limiting the flow paths of the molten mass, several casting cylinders for feeding the casting material into the casting mold are distributed thereon so that the casting mold can be filled simultaneously from several points.

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

Abstract: A device and method for manufacturing a heat sink that has a base and heat radiating fins of various shapes and has a prescribed strength, high heat-radiating efficiency, and whose base and heat-radiating fins are formed integrally. The heat sink manufacturing device includes a die casting machine which has the cavity for a base and heat-radiating fins, and which includes a fixed mold, a movable mold that can move in the vertical or up-down direction, and a slide mold that can move in the horizontal direction.

Abstract: A mold structure includes an upper mold and a lower mold. The upper mold is installed with an upper mold core, and the lower mold is installed with a lower mold core. A mold cavity is formed between the upper mold core and lower mold core. A mother plate disposed in the mold cavity is replaceably coupled to one of the mold cores. The mother plate includes a glass substrate with a metal film thereon. The metal film defines a pattern that is transferred to the plastic material molded in the mold cavity.

Abstract: A fugitive pattern of an article to be investment cast wherein the pattern includes a plurality of locator embossments disposed in an array to provide a datum reference system by which the pattern can be held and positioned by a manipulator, such as for example a gripper device to a computer controlled robotic device, for assembly with another component of the pattern assembly. The datum embossments are located on a portion of the pattern that will be removed from the final metallic casting made to replicate the pattern. The casting includes integral cast datum embossments thereon by which the casting can be held and positioned.

Abstract: A casting machine is provided for producing an as-cast product by using horizontally split type metal molds, which are closed and held horizontally to define a cavity, and by pouring molten metal from a holding furnace into the cavity. The casting machine includes a metal drag held horizontally at a fixed position; a plurality of upwardly-facing cylinders disposed around the metal drag and mounted on a floor or a base, each cylinder having a cylinder rod that extends and retracts; and a cope die base mounted for vertical movement on the distal ends of the cylinder rods of the upwardly-facing cylinders for horizontally holding a metal cope at a position above the metal drag so that the metal cope is mated with the metal drag to define the cavity when the cope die base is lowered by the upwardly-facing cylinders.

Abstract: An engine block mold package is assembled from resin-bonded sand cores in a manner that reduces contamination of the engine block cast in the mold package by loose sand abraded off the cores during assembly. An assembly of multiple cores (core package) of the engine block mold package is formed apart from a base core. The core package is cleaned to remove loose sand therefrom. The cleaned core package then is positioned on the base core followed by assembly of a cover core to complete the engine block mold package for casting of an engine block therein.

Abstract: An engine block mold package includes a barrel crankcase core having a plurality of barrels on each of which a respective cylinder bore liner is disposed. Each cylinder bore liner includes an inside diameter that is tapered along at least a portion of its length to match a draft angle present on the barrels to permit removal of the barrel crankcase core from a core box in which it is formed.

Abstract: An engine block mold package is assembled from resin-bonded sand cores in a manner that reduces parting lines on the exterior surfaces of the mold package. An assembly of multiple cores (core package) is formed and includes multiple inter-core parting lines extending in different directions on exterior surfaces of the core assembly. The core package is disposed between a base core and a cover core configured to enclose the core package and form a single continuous exterior parting line about the assembled mold package.

Abstract: In assembly of engine block mold package, a water jacket slab core is assembled on a barrel crankcase core having a plurality of barrels on which cylinder bore liners are positioned. Some of the barrels include a core print on a distal end thereof. The water jacket slab core includes a plurality of core prints each in mating relation with a respective barrel core print and a plurality of bore liner positioning surfaces that each engage a respective distal end of a respective cylinder bore liner when the water jacket slab core is assembled on the barrels.

Abstract: An interchangeable die system in accordance with the present invention may include two main parts: a shank and a die assembly. The shank is a structural frame that is secured to and remains attached to the die casting machine during a change of the die assembly. The die assembly consists of a die, an adaptor plate and an ejector plate assembly. The die assembly is secured to the shank using the adaptor plate and a locking cam. A spool assembly slides within the shank to actuate the ejector plate assembly.

Abstract: Irregularly shaped mold-core assemblies are retained for casting within a thin-wall container by solid particulate material. In the process, the mold and core elements are formed from the core sand. After the mold and core elements, both of which are formed from core sand, are assembled, the assembly is placed in a container large enough to provide space around the assembled mold and core elements, and solid particulate material is placed in the space around the mold-core assembly to hold the assembled mold and core elements together during pouring of the molten iron alloy into the mold-core assembly and the cooling period, during which the molten iron alloy solidifies to form the casting. After the casting is formed, the solid particles and the core sand from the mold elements and core elements are recovered, processed and reused in further casting operations.

Abstract: A method of molding a jewelry ring having a beveled or rounded inner diameter and a hollow portion in a vertical mold comprises utilizing a multi-piece plug and a soluble insert in a mold to define a mold cavity in the desired shape of the ring or a portion of the ring. A molten material is introduced into the mold cavity and upon hardening forms a ring replica which is removed from the mold by first removing the formed ring replica from the mold halves and then removing the ring replica from the multi-piece plug by separating the multi-piece plug into its individual pieces. The ring replica can be used to form jewelry rings by investment casting.

Abstract: An apparatus for casting a scroll member of a compressor has a first die and a second die. The first die includes a molding surface for molding a base plate of the scroll member. The second die includes a molding surface for molding a scroll wall of the scroll member. The first and second dies define a cavity for casting the scroll member. The first die also includes a first die-member and a second die-member. The second die-member forms a portion of the scroll member, which extends in a direction substantially perpendicular to a direction in which the first and second dies separate from each other.

Abstract: An improved mold for casting motorcycle wheels includes a wider rim cavity having smooth contours to facilitate the flow of molten metal within the mold cavity.

Abstract: Irregularly shaped mold-core assemblies are retained for casting within a thin-wall container by solid particulate material. In the process, the mold and core elements are formed from the core sand. After the mold and core elements, both of which are formed from core sand, are assembled, the assembly is placed in a container large enough to provide space around the assembled mold and core elements, and solid particulate material is placed in the space around the mold-core assembly to hold the assembled mold and core elements together during pouring of the molten iron alloy into the mold-core assembly and the cooling period, during which the molten iron alloy solidifies to form the casting. After the casting is formed, the solid particles and the core sand from the mold elements and core elements are recovered, processed and reused in further casting operations.

Abstract: A method of producing internal screw threads, especially in metals or their alloys and preferably in high strength alloys as are used, inter alia, in dental prosthetics, especially employing the casting technique. Initially an externally threaded pin is positioned in a mold cavity at the location in the dental prosthetic article required for the internal thread. The molten metal is cast around this metal pin and, after hardening of the molten metal, is removed to leave an internal screw thread.

Abstract: A vaporizable refractory coated pattern assembly is formed having a sprue connected to a plurality of thin wall patterns of articles to be cast. The pattern assembly is supported in a refractory particulate media in an open bottom container that is evacuated to subambient pressure and rotated in a manner to distribute particulates to regions of the refractory coated patterns not yet directly contacted by particulates. The pattern assembly is comprised of relatively dense foam plastic pattern material that imparts increased strength to the thin wall patterns. The sprue includes a vent passage that communicates to a particulate media to vent pattern decomposition vapors thereto in a manner that enables faster replacement of the pattern assembly in the media, despite the use of the relatively dense pattern material.

Abstract: A gating system for vertical die casting of a squirrel cage rotor includes an upper end ring cavity, a lower end ring cavity, and a plurality of passages in fluid communication with the upper and lower end ring cavities for forming rotor bars. A gate is radially distanced from the passages, and molten metal is injected into the lower end ring cavity and fills the lower end cavity before filling the passages. The passages are therefore filled at approximately the same time and rate until the passages are full and the upper end ring cavity fills with molten metal.

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.

Abstract: A method of fastening core elements together without the use of foreign agencies, such as adhesives, screws or other such fasteners, uses the same core sand and resin that form the core elements themselves. Core sand elements are retained in an assembly by bodies of cured core sand and resin in holes or cavities that span the interface between the core elements and fasten the core sand elements together. Core sand elements are provided with alignable holes, or cavities, into which a mixture of core sand and a curable resin, preferably the same resin used in forming the core sand elements, is added and the curable resin is cured to provide a body of cured core sand and resin, preferably adhering to the core sand elements, fastening the core sand elements together.

Abstract: An apparatus for casting molded parts includes a casting mold having a lower core, an upper core and pushing elements, which, in a first end position, are in contact so as to form a hollow space into which a liquid casting mass can be introduced during a casting process. The upper core, which rests against the inside of the molded part is displaceable in an insertion direction in order to remove the molded part comprising a hardened casting mass. The upper core has a jacket surface and a bore that extends at a predetermined angle with respect to the insertion direction. An actuating element is displaceable in the insertion direction. An undercut pushing element is coupled to the actuating element via a crossbeam and has a front end that is movable between first and second end positions.

Abstract: The present invention relates to a tool for casting a shaped part for the production of a turbine blade, with several tool blocks which, when assembled with positive engagement in a predetermined manner, form a cavity for the shaped part, into which cavity flowable material can be introduced by means of one or more access apertures. At least one of the tool blocks receives a rotatable or displaceable insert or inset which borders the cavity with a surface and which can be fixed in different positions and/or orientations of the tool blocks, so that different cavity geometries are formed in the different positions and/or orientations of the insert or inset. The tool makes possible a later change of the geometry of the shaped part, in particular of the attack angle, without having to manufacture new tool blocks for this purpose.

Abstract: A method of manufacturing a turbocharger including a housing with a compressor housing portion, turbine housing portion, and a connecting portion is such that an appropriate attitude setting for various portions is preselected, and the housing is then manufactured using a casting technique. The geometry of the connecting portion is circular and concentric with respect to a common center line passing through all three portions.

Abstract: A method of fastening core elements together without the use of foreign agencies, such as adhesives, screws or other such fasteners, uses the same core sand and resin that form the core elements themselves. Core sand elements are retained in an assembly by bodies of cured core sand and resin in holes or cavities that span the interface between the core elements and fasten the core sand elements together. Core sand elements are provided with alignable holes, or cavities, into which a mixture of core sand and a curable resin, preferably the same resin used in forming the core sand elements, is added and the curable resin is cured to provide a body of cured core sand and resin, preferably adhering to the core sand elements, fastening the core sand elements together.

Abstract: A process of fabricating a light alloy casting, such as an aluminum alloy casting, including at least one metal insert includes applying a coating of lampblack to a face of the insert intended to be in contact with the alloy of the component and casting the component with the molten alloy in a mold cavity in which the insert is positioned. Applications include fabricating engine blocks with integrally cast liners made of cast iron.

Abstract: A device for manufacturing an engine block has a casting mold with mold parts and cylinder liners. The mold parts have a seat with seat surfaces for each cylinder liner, and the opposed ends of the cylinder liner are seated in the seat surfaces. The cylinder liners become connected to the material cast in the casting mold and are removed together with the cast material from the mold parts after casting. The seat surfaces are conical and inclined at an incline angle relative to the cross-sectional plane of the cylinder liner seated in the seat such that the opposed ends of the cylinder liner remain seated at the seat surfaces upon heat expansion of the cylinder liner during preparation of the casting mold for casting and during casting.

Abstract: The lost foam method of casting a cylinder liner with water jacket comprises the steps of creating a blank identical to the liner desired, with a drain defined therein, from a heat-dissipated material such as styrofoam, coating the blank with core wash, placing the blank into a casting mold, filling the mold and a chamber defined within the blank with sand, pouring hot metal into the mold, extracting the formed metal liner from the mold, draining sand from within the chamber and plugging the sand drain.

Abstract: A multi-wall ceramic core assembly and method of making same wherein a plurality of individual thin wall, arcuate (e.g. airfoil shaped) core elements are formed in respective master dies to have close tolerance mating locating features that substantially prevent penetration of molten metal between the interlocked features during casting, the individual core elements are fired on ceramic supports to have integral locating features, the prefired core elements are assembled together using the locator features of adjacent core elements, and the assembled core elements are held together using a fugitive material. The multi-wall ceramic core assembly so produced comprises the plurality of spaced apart thin wall, arcuate core elements and located by the mated close tolerance locating features.

Abstract: A casting die comprises upper and lower dies, each having integral projections for forming holes in a resulting die-cast product. When the upper and lower dies are engaged together, their respective projections are matched and contacted with one another to define bridge-like inner die elements between the two dies, so that holes may be readily formed via those inner die elements in a product being cast in the dies.

Abstract: A gas turbine engine airfoil is cast around a core having a plurality of legs to form matching flow channels in the airfoil. The legs have a tie extending therebetween to maintain alignment. And, the tie is relocated along the core span to reduce differential static pressure of the cooling air across the resulting tie hole formed by the core tie.

Abstract: The invention overcomes prior art problems associated with mass-production of technology-based commercial products like watch cases, mobile telephone housings, medical appliances, etc. such as high investment in tooling, delays in production, short economic tool life, inconsistence and mismatching between parts made in different geographical locations, etc., through the use of standardized, interchangeable ceramic mold inserts.

Abstract: A one piece cast wheel having a lightener recess formed in the wheel disc which extends axially beneath the wheel outboard tire bead seat. A method of casting such a one piece wheel which utilizes a multi-piece wheel mold having side members which include a plurality of components. A core for forming the lightener cavity is formed integrally with the side member components. The side member components are sequentially moved relative to each other to release the core from the lightener cavity.

Abstract: An apparatus for casting molded parts includes a casting mold having a lower core, an upper core and pushing elements, which, in a first end position, are in contact so as to form a hollow space into which a liquid casting mass can be introduced during a casting process. The upper core, which rests against the inside of the molded part is displaceable in an insertion direction in order to remove the molded part comprising a hardened casting mass. The upper core has a jacket surface and a bore that extends at a predetermined angle with respect to the insertion direction. An actuating element is displaceable in the insertion direction. An undercut pushing element is coupled to the actuating element via a crossbeam and has a front end that is movable between first and second end positions.

Abstract: A continuous casting installation comprises an ingot mould and an oscillating holding device used for causing the ingot mould to swing when in a casting position. The installation consists, in a separable manner, of an interchangeable part and a stationary part. To replace the intechangeable part, it is separated from the stationary one and moved using a conveying means, at least along a partial path, from its position of operation into an area beneath the casting position. This enables, especially in the multiline casting installations, the interchangeable part to be transported during the casting process and, for example, along paths comprising straight or arciform segments, to any purposefully selected position and to be replaced by a new interchangeable part to be replaced in multiline installations with no interference with the casting process in any adjacent ingot arrangement.

Abstract: A casting machine is disclosed having a quick-change tie bar mechanism. This mechanism includes an actuator having a rod coupled to a first bearing member and a body coupled to a second bearing member. The first and second bearing members are configured to reciprocally move in opposite directions in response to extension and retraction of the rod relative to the body. The bearing members have a first configuration for engaging a nut threaded on a tie bar to fix the tie bar in relation to a platen through which the tie bar extends. The first and second bearing members also have a second configuration for releasing the tie bar to permit removal through the platen so that a part may be accessed for removal and/or replacement. In another embodiment, a number of platens are included as are a number of tie bars configured to guide movement of one of the platens relative to another.

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.

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.

Abstract: A plurality of individual thin wall, arcuate (e.g. airfoil shaped) core elements are formed in respective master dies to have integral interlocking locating features, the individual core elements are prefired in respective ceramic setter supports to have integral locating features, the prefired core elements are assembled together using the locator features of adjacent core elements, and the assembled core elements are adhered together using ceramic adhesive introduced at internal joints defined between mating interlocked locating features. The multi-wall ceramic core assembly so produced comprises the plurality of spaced apart thin wall, arcuate core elements and joined together by at the internal joints defined between the adhered interlocked locating features.