Abstract: An improved, more economical mold for use in continuously casting metals or alloys comprises a mold tube and a pair of flanges, one flange peripherally disposed of and in abutting, liquid sealing relation with each end of the tube. Such sealing relation is preferably provided by a continuous knife-edged protrusion formed in and disposed peripherally of each flange and adapted to sealingly cooperate with a continuous shallow groove formed in and disposed peripherally of each end of the tube. Cooling means including a jacket and a baffle surround the tube between the flanges, and the baffle further defines a channel immediately circumjacent a substantial portion of the outer surface of the tube for directing a flow of cooling liquid about the tube in direct contact with such surface.

Abstract: The free energy of a metal which will fill the sinkhead of an ingot mold is calculated by assuming the dimensions of a liner sized to achieve the selected sinkhead volume and calculating the maximum temperature which the liner would achieve upon filling the sinkhead with a molten metal. The free energy is maximized until the mass of the liner is minimized at a calculated temperature less than the melting temperature of the liner. A liner is formed having dimensions corresponding to those of the calculated minimum mass liner. The liner is inserted into a support structure which will rest on the ingot mold.

Abstract: A casting core adapted to be placed inside a molding cavity for defining a cored-out hollow inside a metal casting, which core comprises a first coated layer formed on an exterior surface of the casting core by coating a slurry containing powdery refractory material, and a second coated layer formed over the first coated layer by applying a solution containing graphite particles. A method of making a metal casting with the use of the casting core is also disclosed.

Abstract: A core setter for use in setting one or more cores in the mould impression in the rearmost of a number of mould parts placed face to face during conveyance towards a pouring line. The setter consists of an essentially L-shaped swingable arm (1), which is pivotally journalled around a vertical axis (2) and at its free end, opposite the pivot, is provided with a core-retaining device (10), designed to accept cores in a position outside the moulding system and to deliver these into the mould impressions by a translational movement of the core-retaining device in the direction of conveyance of the mould parts.

Abstract: A mold for casting cylinder blocks of combustion engines in an upright position includes a cope and a barrel core located therewith for defining a cylinder bore. A drag defines a crank space and is configured for cooperating with the cope to define a cylinder block such that the drag and cope can be stripped in an axial direction with respect to the cylinder bore.

Abstract: A mold structure has a plurality of article molds disposed in an array with an open central space. A gating system is connected with upper ends of the article molds and a base is connected with lower ends of the article molds. A baffle plate is inserted into the open central space between the article molds. The baffle plate has an area which is greater than the area of an opening in the base. A lower side of the baffle plate overlies an area on the base which extends completely around the opening in the base. To insert the baffle plate through the opening in the base, a slit is formed in the baffle plate. A portion of the base is received in the slit and then the baffle plate is rotated to turn it through the opening in the base. An alternative method of inserting the baffle plate is by partially folding the baffle plate and inserting the folded baffle plate through the opening in the base of the mold structure.

Abstract: A sealing structure is disposed between a metal-casting ingot mold bottom portion and a bottom plate to prevent the leakage of molten steel between the mold and plate. A clay rope disposed in a closed configuration corresponding to the bottom of the ingot mold is affixed to the cardboard sheet with an adhesive system. Overlapping portions of the cardboard sheet are grasped to position the clay rope directly under the ingot mold, and the mold is lowered onto the bottom plate. Hot glue (or pressure sensitive adhesive tape and/or white glue) holds the clay rope on the cardboard sheet. The clay rope is offset at a central portion of the sheet to allow folding of the sheet for transport.

Abstract: Sand molds stored in a prepour storage system are retrieved and conveyed to a pouring station with a total mold cavity capacity equal to the amount of molten metal to be poured. Despite the fact that the mold cavities vary in size they are delivered to the pouring station in a sequence that accomodates delivery of the molds having variable metal capacity to one of a plurality of cooling conveyor lines so that each cooling line conveys molds which require variable lengths of time to cool before such molds can be conveyed into a punchout where the cope flask is stripped and the sand mass and castings are pushed up from the drag flask and onto a shakeout which conveys sand to a reclaim system and castings to a processing area where the castings are shot blasted, gates and risers are removed, the castings are inspected, flame washed, welded (as needed), ground, chipped, heat treated and then blast cleaned a second time before final grinding, chipping, gauging, final inspection, assembly and storage.

Abstract: A plurality of identical green sand molds are sequentially formed by horizontal compaction on automatic mold making machinery. Each mold has a front and back vertical face with a recess formed in the front face and a plurality of down runners formed in the back face. A mold piece insert is formed of a mixture of green sand and a chemical bonding agent, preferably a resin binder and cold set in a pattern box to form the cavities for the cast articles. The mold piece insert is received flush in the mold front face recess with the cavities opening to the front face. A plurality of molds, with inserts, are adjoined in front-to-back relationship with the down runners overlapping the cavities for feeding the molten pour thereto.

Abstract: A production casting line includes a foam pattern former producing destructible foam patterns for the forming of cast parts. A pattern clusters inventory station is provided immediately adjacent to the process line having a plurality of different preformed foam pattern clusters which are immediately available for introduction and insertion into the production line by interposing of the same into the process line. A substantial number of different patterns are stored. The foam patterns are stable, can be inventoried for long periods and are relatively inexpensive. The versatility with the inventoried patterns increases the operating efficiency and reduce the overall cost of the manufacturing operation. The cast line includes flasks within the pattern clusters and are mounted at a receiving station. Sand is compacted about the foam pattern.

Abstract: Both a pattern member and a body of expansion material are covered with a layer of ceramic mold material. The body of expansion material has a coefficient of thermal expansion which is greater than the coefficient of thermal expansion of the ceramic mold material. The layer of ceramic mold material and the body of expansion material are heated. This results in a cracking of the layer of ceramic mold material by the body of expansion material due to greater thermal expansion of the body of expansion material as it is heated. During the step of heating the ceramic mold material and body of expansion material, the pattern member is melted to separate the pattern from the layer of ceramic mold material.

Abstract: An adhesive paste composition containing in admixture a resin component, a hardener component, a hydrophobic filler component and a curing agent. The resin component includes a polyol having at least two hydroxyl groups and the hardener component includes a liquid polyisocyanate containing at least two isocyanate groups. The admixture may be made by mixing together a premixed resin component contianing a filler and a catalyst and a premixed hardener component containing a hydrophobic filler. The fluid in the resin component, the hardener component, or both may be a thixotropic agent.

Abstract: An apparatus and method for detecting the misalignment of cooperating mold sections is provided. The apparatus and method utilize a mold making machine which includes a device for forming a cavity of predetermined shape in the interior of each mold section and a device for forming a reference mark on the exterior of the mold surface, a conveyor for transporting the molds along a predetermined path from the mold making machine to a mold pouring station, and a non-contact distance measuring device for detecting the misalignment of the internal mold cavities of the mold sections by detecting any misalignment in the external reference marks.

Abstract: The system includes: (a) a hollow cylindrical body adapted to be mounted in a casting table, (b) an annular water baffle removably mounted in the body, the baffle having a central opening through which a forming ingot passes and the baffle providing a flow path for cooling water to flow radially inwardly from the body and discharge inwardly and downwardly against a forming ingot passing through the central opening, (c) an annular mould removably mounted in the body immediately above the water baffle having a central forming cavity for forming a metal ingot, the forming cavity having a smaller diameter than the central opening of the water baffle, (d) a feed inlet for molten metal comprising an insulating ring removably mounted within the body immediately above the mould, the outer diameter of the insulating ring being less than the diameter of the body, (e) a pressure ring removably mounted in the body in the annular gap between the body and the outer diameter of the insulating ring, and (f) a cover plate ada

Abstract: An improved method of assembling molds enables the size of successive molds to be adjusted to provide cast articles having a desired size. In practicing the method, a first or initial mold is assembled in a fixture. This initial mold is used to form a cast article. The cast article formed in the initial mold is measured to determine the extent to which the dimensions of the article deviate from predetermined design dimensions. The fixture is then adjusted to compensate for the deviations in the dimensions of the cast article from the intended or design dimensions. A second mold is then assembled in the fixture. Since the fixture has been adjusted to compensate for the inaccuracies in the first mold, a product cast with the second mold will have dimensions closer to the desired dimensions.

Abstract: A mold for continuous casting has indents, grooves, or recesses in the mold wall itself and/or along one or more edges thereof; wear-proof inserts are fitted into these grooves or indents and fastened thereto by means of electron beam welding along exposed joint lines between the inserts as inserted and border edges of the indents or recesses. The inserts are affixed in this manner along edges for engagement with other mold walls, and/or along the lower edge and/or a level which is expected to coincide with the surface level of the molten steel in the mold.

Abstract: A device for damping vibrations of an overhead conductor comprises a die cast weight and housing comprised of opposed weight and housing halves located on opposed sides of a clamp arm and having spherical outer surfaces to minimize corona and tooling costs. The clamp arm is located between two tubular elastomer damping elements secured in place between the clamp arm and the weight and housing halves. The damping device, in addition, includes a pin that secures the weight and housing halves, clamp arm, and damping members together in a sandwich-like construction.

Abstract: In a forcibly cooled casting apparatus including a lower surface plate and an upper cooling plate covering the lower surface plate with a casting mold therebetween, a plurality of tube members extend through the casting mold and having a lower end supported on a receiving base of the surface plate and an upper end received in a positioning hole of the cooling plate. A sleeve provided on the cooling plate supports a protection case within which extends a cooling nozzle which passes through the cooling plate. The cooling nozzle is connected to a source of cooling fluid and has a tapered tip which fits in the upper end of the tube member so that cooling fluid can flow through the tube member. A spring compressed within the protection case biases the cooling nozzle into fluid tight contact with the tube member. A detector is provided for detecting improper positioning of the cooling nozzle.

Abstract: An improved mold includes an upper mold section having a primary distribution system which is connected with a furnace and a lower mold section which is withdrawn from the furnace on a chill plate. A baffle plate is supported from the primary distribution system. The lower mold section includes a secondary distribution system which is connected in fluid communication with the primary distribution system at separable joints. The secondary distribution system is connected in fluid communication with article molds which are disposed in an annular array. During pouring of molten metal, reaction forces are transmitted to the chill plate from the pour cup through a support post and baffle plate. Once the article molds have been filled with molten metal, the chill plate is lowered. The primary distribution system which is connected to the furnace, remains stationary.

Abstract: An arrangement for the exchange of implements in foundry or mold casting hines, in which the implement is moved from a changing station towards an implement receiving and work station, and there connected with the implement holder.

Abstract: Graphite mold blocks with liquid coolant sprays located in bores extending through the blocks. A sleeve for retarding the cooling of the mold adjacent the spray entrance ends of the bores serves to reduce the temperature differential along the height of the block.

Abstract: In order to maintain fluid tight seals between open ended article mold cavities and a chill plate and to prevent cracking of article molds at connections with a base plate, the base plate has sections which can be moved relative to each other under the effect of thermal expansion forces transmitted from a molten metal distribution system connected with the upper ends of the article molds. The base plate may be formed as one piece with stress concentration areas. During the casting of articles, stresses in the base plate crack the base plate at the areas of stress concentration to form the separate sections of the base plate. The areas of stress concentration can be formed by slots or grooves in the base plate. The areas of stress concentration can also be formed by bodies of expansion material having a greater coefficient of thermal expansion than the ceramic material of the base plate.

Abstract: A riser sleeve has at its end which is uppermost when the sleeve is located in the mould a holding member which can be engaged by a mechanical holding device so as to adapt the sleeve to automatic handling. The holding member may be for example a disc, ring or solid or hollow cylinder and may be formed integrally with the sleeve or formed separately and fixed to the sleeve. By adopting a standard shape and size for the holding member for a wide range of sleeve shapes and sizes the same holding device can be used to handle the whole range of sleeves.

Abstract: Chain forming dies having inner surfaces shaped to form a desired number of linked chain elements. The dies are adapted to close against one another and a casting gate to each chain element forming section is provided. The connection for the chain elements are formed by a die insert inserted in a groove between each chain element forming section. The die insert simultaneously forms holes on extrusions of each chain element and axial posts on the mating end of each adjacent chain forming element. Means are provided to position the die insert when the chain forming dies are closed against each other. Mating coupler elements are formed by coupler-shaped sections in the chain forming dies.

Abstract: A method and a die mold for molding destructible investment casting patterns of irregular shapes such as, for instance, investment casting patterns utilized in the production of vane sections for a jet engine turbine, or the like. The die mold comprises a mold cavity defined by surfaces extending arcuately in non-parallel relation, and includes a plurality of separable mold portions including rear, front, and side mold portions preferably movable outwardly with respect to one another and with respect to a mounting base, and also including coacting movable mold cavity insert portions disposed intermediate the first mentioned mold portions, and defining arcuate surface sections of the mold cavity.

Abstract: The space between the open bottom mold and the supporting stool used for casting ingots is sealed by placing a thin wall steel tube between the mold and the stool. The weight of the mold partially collapses the tube causing the surfaces of the tube to conform to both the surfaces of the mold and the stool, thus forming a seal.

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

Abstract: A foundry mould for low pressure moulding of metal parts is constructed of a mould chamber (14) with a bottom surface (17) having an opening (31) through which molten casting metal can ascend. A peripheral pressure chamber (15) surrounds the side walls of the chamber (14) and a suction bell (18, 19) connected to a suction duct (23) covers the top of the mould chamber and pressure chamber. Communicating apertures (20, 21) provide gas flow paths from the mould chamber and pressure chamber to the suction bell. Patterns of gasifiable expanded polystyrene are located in the mould chamber and are supported therein by a masking device, such as a masking shell (28), by means of pattern appendages (26) connected to tubular supporting members (27) of the masking shell. A sleeve (34) is locked to the opening (31) and supports the masking device. Compacted, binderless, sand fills the remaining volume of the mould chamber.

Abstract: A horizontal casting technique and mold for use specifically with shell molds and runner feeder sections. The runner feeder sections are assembled within the shell molds such that the ends of the runner feeder section protrude from the mold and can be flow connected to a runner feeder of an adjacent assembly. A plurality of these assemblies constitute the horizontal mold having a horizontal runner feeder and a plurality of shell molds in spaced, side-by-side relationship.

Abstract: A method is disclosed for increasing productivity when casting Vee configuration engine blocks in a given size, two-part refractory mold having a single parting plane.

Abstract: A mold for use in an apparatus and process utilizing an electromagnetic field to stir a molten metal or metal alloy comprises a plurality of laminations of thermally and electrically conductive material separated by electrically insulating material. The electrically insulating material is oriented to minimize at least some of the flow path lengths of currents induced in the mold whereby magnetic induction losses caused by the mold are substantially reduced and the stirring efficiency is enhanced.

Abstract: A method for moulding multiple castings in which each mould is fed from a source of molten metal through a thin slit the width of which lies in the range 1.25 mm down to 0.25 mm. The cast articles can easily be removed from the runner and riser system after casting without a machining operation so that the casting moulds can be packed closer together and more castings can be produced from each mould assembly. The thin slit also acts as a filter. A particular mould assembly seen in FIG. 2 is cylindrical and comprises a plurality of wedge-shaped mould segments 2 having mould cavities 4 in abutting faces. A central runner passage 6 is formed when the mould segments are assembled and the metal flows into the mould cavities through narrow slits 10 in one edge of each mould. After casting and removal of the mould the narrow flashing formed in the slits can easily be broken to remove the cast articles from the metal formed in the central runner passage.

Abstract: A hypereutectic aluminum-silicon casting alloy having particular use in casting cylinder blocks for marine engines. The alloy is composed by weight of 16% to 19% of silicon, 0.4 to 0.7% magnesium, up to 0.37% copper and the balance aluminum. With the stated silicon content the alloy has good fluidity and the precipitated silicon crystals provide excellent wear resistance. In addition, the alloy has a narrow solidification range of less than 150.degree. F., thereby providing the alloy with excellent castability. The copper content is maintained at a minimum so that the alloy has improved resistance to salt water corrosion.

Abstract: A disposable sprue cup for use in a metal casting process using a mold pattern embedded in unbound process sand having a grain size, the disposable sprue cup being made of bonded sand having a grain size substantially equal to the grain size of the process sand and having a binder that breaks down under the heat of resident metal remaining in the cup after the casting process is completed.

Abstract: An improved core is adapted to extend axially through the central portion of a mold cavity in which an airfoil or other article is formed. The core is used to form cooling passages as the airfoil is cast in the mold cavity. The core has an elongated cantilevered center section which is disposed within a main or base section. A metallic pin member extends from a free end portion of the cantilevered center section of the core to the main section of the core to hold the free end portion of the cantilevered center section against movement relative to the main section.

Abstract: In the ingot casting of killed-steel steels, insulative walled reservoirs known as hot-tops are employed at the top of the mold to maintain a source of molten steel which can feed the shrinkage cavity that forms during solidification of the ingot. Presently, these hot-tops are set to a predetermined height prior to the filling of the mold cavity. As a result of such controlled height pourings, variations in the volume of the mold cavity lead to significant losses in the ingot-to-product yield. To overcome such losses, the invention employs a floating hot-top. Rather than teeming to a prescribed height, the ingot is teemed to a prescribed weight and the floating hot-top is placed on the surface of the steel so teemed. Further pouring is delayed, at least until the hot top is welded to the surface by the freezing of the molten steel in contact therewith. Thereafter, the hollow center of hot-top is filled to provide a sufficient reservoir of molten metal for the resultant shrinkage cavity.

Abstract: Castings are produced by sandwiching a central mould part 10 between two outer mould parts 36, 38 during the casting process. The central mould part 10 is then transfered sequentially from between the outer mould parts 36, 38 and subsequently re-located between the outer mould parts in a vacant, relatively cool, and dry condition for the production of a further casting. In one embodiment a plurality of central mould parts are transferred sequentially from the outer mould parts to a removal station 45, a quenching station 50, and a drying station 70, before being returned to the central mould parts.

Abstract: A plug for closing the opening in the bottom of a top pouring ingot mold is comprised of a preformed plug body having top and bottom ends and an outer peripheral surface providing a contour generally corresponding with that of the mold opening to be plugged. The lower portion of the outer peripheral surface is provided with a coating of a thermally curable sealing composition having a heavy paste-like consistency, and the plug body and coating are enclosed in a heat shrinkable plastic film. In use, the plug is pushed into a plug opening in the bottom of an ingot mold which generally is hot from a previous casting operation, the plastic film disintegrates, the sealing material is squeezed so as to spread and fill the space between the mold opening and plug body, and the heat of the mold cures the sealing material to secure the plug in place and seal the peripheral space between the plug body and mold opening.

Abstract: A method of casting or moulding an internally screw-threaded article comprises introducing casting or moulding material around two withdrawable flat core members which overlap within a mould cavity. The leading end face of each core member is formed with a male segment of the female screw thread to be formed in the article, the arrangement being that when the core members meet one another the two screw thead segments of the two core members are located to form two diametrally opposite segments of a male image of said female screw thread, withdrawing the core members from the mould cavity when the casting or moulding material has set and removing the cast article from the mould cavity.

Abstract: The invention relates to a mould assembly including a plurality of individual moulds. The mould assembly of the present invention is made by separately transfer moulding a starter base 16, a plurality of moulds 12, a downpole 14 and pouring cup 19, providing each with mechanical locking features, such as screw threads, and joining them together into the assembly. Much greater flexibility is thereby achieved in materials and wall thicknesses, which can be different in different parts of the assembly to suit strength and heat transfer requirements, individual bits can be replaced, and the transfer moulding produces a compact homogeneous ceramic structure.

Abstract: The subject invention is a process for improving the performance capacity of chaplets or spacer supports as used in metal casting as supports adjacent the mold cavity, said process comprising the steps of immersing the chaplet into a water-based solution of borax and thereupon employing the chaplet in the molding process with said solution covering the chaplet.

Abstract: A method of casting metal in a gas permeable shell mold in which a vacuum is applied to an external upper mold surface by engaging the mold in the downwardly facing opening of a generally cylindrical vacuum chamber, defined by a chamber wall with a threaded region sized and shaped to snuggly engage a side mold surface. Engagement is effected by forcing the mold into the chamber opening while causing relative rotation of the mold and chamber.

Abstract: Guide and runner assemblies for uphill teeming comprise a refractory tube in a sheath with an optional body of particulate material between the inner tube and sheath. The sheath may be combustible.

Abstract: A process and apparatus for producing a metallic laminar composite material utilizes a pressure tank, a ladle, and a dip tube for transferring molten metal into a mold which has a metallic plate suspended within it. The molten metal is supplied by the ladle and the dip tube in such a way that slag and scum existing on the surface of the molten metal are not introduced into the mold. Prior to introducing the molten metal into the mold, the mold is purged with an inert gas to prevent oxidation of the surface of the metallic plate. The mold is made of freely movable carbon segments which permit easy assembly and disassembly of the mold for varying the size of the molding chamber.

Abstract: Process for obtaining, by pig iron casting, machine elements provided with protection cages suitable to preserve delicate portions of machine elements from breaking and deforming during the production phase. The process consists in applying raised impressions of the cages on a pattern for green casting which impression corresponds to a print of a hardened shell reproducing the outer portions of the machine elements.

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

Abstract: Novel method and means for securely attaching a liner of insulation boarding to the mold cap of a two-piece ingot mold, in order that the ingot mold will be capable of producing substantially void-free ingots.

Abstract: An ingot mold with mold wall and stool shields and the method of installing the mold wall and stool shields to the ingot mold and stoll. The mold wall shield comprises at least two portions connected by a bend. The mold wall shield and the stool shield can be multi-layered to provide a thin envelope or layer of air between the parallel layers. The shields are nailed to the mold or stool by an explosion actuated hammer. The mold wall shield is installed with the bend near the intersection between the mold and the stool. The shields are made of similar material to that being cast and melt due to the heat of the molten metal in the mold.

Abstract: A permanent mold is equipped with a core pulling device covered with a thin sand jacket, that can be peeled off, in order to produce unregular caves in the cast.

Abstract: A set of half molds mounted so that they are movable on a base and when drawn together, form a split mold which can be taken apart upon separation, the half molds have spaces which form slit gates communicating with a metal receiver and the central cavity of the half molds, whose surfaces form the surfaces of the casting. At least one of the side surfaces of the slit gate-forming spaces is made step-shaped in the direction of molten metal level so that upon the drawing together of the half molds, the accuracy in raising the level of the molten metal may be enhanced.