Utilizing Particular Shaping Surface Material Patents (Class 164/138)
  • Patent number: 10363605
    Abstract: A mold half, especially for blow molding of thermoplastic articles, has a mold body defined at least in part by a single piece of aluminum or aluminum alloy mold material having a cavity and a pinch-off or other feature area and further having a metal-matrix composite (MMC) layer formed integrally in the mold body at the pinch-off or other feature area. A mold is fabricated from two mated mold halves. A process of producing a mold half involves machining a single piece of mold material to provide a mold body having a cavity and a pinch-off or other feature area, the pinch-off or other feature area being of smaller dimension than required for the mold half, integrally forming a metal-matrix composite layer in the pinch-off or other feature area to build up the pinch-off or other feature area to at least a dimension required for the mold half. The metal-matrix composite comprises an aluminum-nickel alloy matrix (e.g. AI-12Si alloy alloyed with Ni) having WC particles embedded therein or a aluminum matrix (e.g.
    Type: Grant
    Filed: July 21, 2011
    Date of Patent: July 30, 2019
    Assignees: National Research Council of Canada, Garrtech Inc.
    Inventors: Lijue Xue, Shaodong Wang, Yangsheng Li, Tony Paget
  • Patent number: 10226813
    Abstract: Provided are a method of manufacturing an aluminum-zinc-based alloy sheet using twin-roll casting and an aluminum-zinc-based alloy sheet manufactured thereby. Specifically, a method of manufacturing an aluminum-zinc-based alloy sheet, including preparing a melt by melting elements corresponding to an aluminum alloy including 0.5 wt % to 10 wt % of zinc, inevitable impurities and aluminum as a balance (step 1); and twin-roll casting by introducing the melt prepared in step 1 between a pair of rotating cooling rolls (step 2), and an aluminum-zinc-based alloy sheet manufactured thereby are provided. The present invention may manufacture an aluminum-zinc-based alloy sheet, in which twin-roll casting is known to be difficult due to a wide solid-liquid coexistence region, by twin-roll casting by using cooling rolls having high thermal conductivity and controlling a reduction force by the rotational speed of the rolls.
    Type: Grant
    Filed: October 16, 2013
    Date of Patent: March 12, 2019
    Assignee: Korea Institute of Machinery and Materials
    Inventors: Hyoung-Wook Kim, Yun-Soo Lee, Cha Yong Lim, Jae Hyung Cho
  • Patent number: 10195793
    Abstract: A water-soluble insert for use in joining pipes, made of a material comprising a salt selected from the group consisting of KCl, Na Cl, and mixtures thereof; and MgO. Upon addition of a small amount of water to the material, the MgO reacts with hygroscopic impurities in the chloride salt to provide a material with superior properties. The insert is cast from the material, in general by being placed on a form and compressed. Also disclosed is the use of the insert in joining the ends of two pipes, especially pipes made from thermoplastic. The insert is placed in the matching pipe ends, which are then welded. After the join is complete, water is flowed through the pipe, dissolving the insert.
    Type: Grant
    Filed: July 29, 2014
    Date of Patent: February 5, 2019
    Assignee: IMI TAMI INSTITUTE FOR RESEARCH AND Development LTD.
    Inventors: Gideon Shikolski, Eyal Barnea, Ezra Hanuka, Dorit Canfi
  • Patent number: 10076868
    Abstract: A method of producing an injection molding tool for molding an article includes producing a replica of the article using at least one of an additive manufacturing process, a solid freeform fabrication process, or a computer numerically controlled (CNC) process. A support block is configured to receive at least a portion of the replica and support the replica with at least one of an outer peripheral surface of the replica or an inner peripheral surface of the replica positioned at a spaced distance from a peripheral surface of the support block. The replica is supported inside the support block at the spaced distance, a ceramic resin material is introduced into the spaced distance and cured to form a ceramic shell insert, the insert is removed from the cavity, and the insert is positioned within the support block to form a part of a mold tool adapted for installation in a standard plastic injection molding machine.
    Type: Grant
    Filed: January 12, 2018
    Date of Patent: September 18, 2018
    Assignee: Capital One Services, LLC
    Inventor: David K. Wurmfeld
  • Patent number: 9873151
    Abstract: Disclosed are embodiments of a vessel configured to contain a secondary magnetic induction field therein for melting materials, and methods of use thereof. The vessel can be used in an injection molding apparatus having an induction coil positioned adjacent to the vessel. The vessel can have a tubular body configured to substantially surround and receive a plunger tip. Longitudinal slots or gaps extend through the thickness of the body to allow and/or direct eddy currents into the vessel during application of an RF induction field from the coil. The body also includes temperature regulating lines configured to flow a liquid within. The temperature regulating lines can be provided to run longitudinally within the wall(s) of the body between its inner bore and outer surface(s). A flange may be provided at one end of the body to secure the body within an injection molding apparatus.
    Type: Grant
    Filed: December 16, 2014
    Date of Patent: January 23, 2018
    Assignee: Crucible Intellectual Property, LLC
    Inventors: Sean Timothy O'Keeffe, Adam A. Verreault, Glenton Jelbert, Michael Deming
  • Patent number: 9512535
    Abstract: A method for manufacturing a moth-eye mold of an embodiment of the present invention employs a mold base including a metal base, an organic insulating layer provided on the metal base, and an aluminum alloy layer provided on the organic insulating layer, the aluminum alloy layer containing aluminum and a non-aluminum metal element M, an absolute value of a difference between a standard electrode potential of the metal element M and a standard electrode potential of aluminum being not more than 0.64 V, and a content of the metal element M in the aluminum alloy layer not exceeding 10 mass %.
    Type: Grant
    Filed: March 29, 2012
    Date of Patent: December 6, 2016
    Assignees: SHARP KABUSHIKI KAISHA, GEOMATEC CO., LTD.
    Inventors: Akinobu Isurugi, Kiyoshi Minoura, Hiroyuki Sugawara
  • Patent number: 9162280
    Abstract: A hybrid ceramic/sand casting method of manufacturing a metal part. The method is especially suitable for manufacturing engine cylinder blocks or cylinder head, which have very small internal passages or other very small internal features. These parts are formed using a hybrid core having at least one ceramic section and at least one sand section, with the ceramic section being used to create the internal feature. A mold cavity is created for the part, and the hybrid core is positioned in the mold. Molten metal is introduced into the mold, and after the metal cools, the core is removed, thereby forming the part with the internal feature.
    Type: Grant
    Filed: July 23, 2013
    Date of Patent: October 20, 2015
    Assignee: SOUTHWEST RESEARCH INSTITUTE
    Inventors: Barry E. Westmoreland, Douglas A. McKee, Marc C. Megel, Mark A. Tussing, Thomas E. Reinhart, David P. Branyon
  • Patent number: 8844897
    Abstract: Devices may be in contact with molten metals such as copper, for example. The devices may include, but are not limited to, a die used for producing articles made from the molten metal, a sensor for determining an amount of a dissolved gas in the molten metal, or an ultrasonic device for reducing gas content (e.g., hydrogen) in the molten metal. Niobium may be used as a protective barrier for the devices when they are exposed to the molten metals.
    Type: Grant
    Filed: March 4, 2009
    Date of Patent: September 30, 2014
    Assignee: Southwire Company, LLC
    Inventors: Victor F. Rundquist, Kevin S. Gill
  • Patent number: 8826966
    Abstract: A tubular melt containment member for transient containment of molten metals and alloys, especially reactive metals and alloys, includes a melt-contacting layer or region that comprises an oxygen-deficient rare earth oxide material that is less reactive as compared to the counterpart stoichiometric rare earth oxide. The oxygen-deficient (sub-stoichiometric) rare earth oxide can comprise oxygen-deficient yttria represented by Y2O3-x wherein x is from 0.01 to 0.1. Use of the oxygen-deficient rare earth oxide as the melt-contacting layer or region material reduces reaction with the melt for a given melt temperature and melt contact time.
    Type: Grant
    Filed: August 30, 2012
    Date of Patent: September 9, 2014
    Assignee: Iowa State University Research Foundation, Inc.
    Inventors: Joel R. Rieken, Andrew J. Heidloff
  • Patent number: 8714233
    Abstract: A casting process for producing metal alloy castings, facecoats and apparatuses suitable for carrying out the process, and castings produced by the process. The casting process entails the use of a mold having a cavity with a continuous aluminum-containing solid facecoat on its surface. A molten quantity of a metal alloy is introduced into the mold cavity so that the molten alloy contacts the solid facecoat. The mold is then allowed to cool to solidify the molten alloy and form a cast product. During the casting process, aluminum in the solid facecoat diffuses into the cast product to form an aluminum-containing surface region at the casting surface. Following removal of the cast product from the mold, an alumina-containing scale grows on the casting surface as a result of oxidation of the casting surface region.
    Type: Grant
    Filed: March 29, 2011
    Date of Patent: May 6, 2014
    Assignee: General Electric Company
    Inventors: George Albert Goller, Dennis William Cavanaugh
  • Patent number: 8662146
    Abstract: The present invention provides a structure for casting containing an organic fiber, an inorganic fiber, inorganic particles (A) having an average particle diameter of 50 to 150 ?m, and a binder (a), having a surface layer containing refractory inorganic particles (B) having an average particle diameter of 1 to 100 ?m selected from metal oxides and metal silicates, a clay mineral, and a binder (b), on the surface of the structure.
    Type: Grant
    Filed: June 24, 2011
    Date of Patent: March 4, 2014
    Assignee: Kao Corporation
    Inventor: Haruki Ikenaga
  • Patent number: 8657252
    Abstract: A surface-treated mold that includes a mold, a metal layer that is provided on a surface of the mold and contains at least one metal selected from nickel, chromium, tungsten and brass, and a carbon film that is provided on a surface of the metal layer, wherein the metal layer contains carbon, and the carbon concentration in the metal layer is higher between the boundary with the carbon film and the center of the metal layer than that between the boundary with the mold and the center of the metal layer.
    Type: Grant
    Filed: November 12, 2010
    Date of Patent: February 25, 2014
    Assignee: Toyota Jidosha Kabushiki Kaisha
    Inventors: Yuichi Furukawa, Jun Yaokawa, Yasushi Iwata
  • Patent number: 8646745
    Abstract: A mold includes: a base; and a contact surface which is provided on the base and which comes into contact with a molten material. The contact surface is provided with a first surface portion that includes a first fiber layer in which first carbon fibers are raised, and a second surface portion having different surface characteristics from the first surface portion.
    Type: Grant
    Filed: January 24, 2011
    Date of Patent: February 11, 2014
    Assignee: Toyota Jidosha Kabushiki Kaisha
    Inventors: Jun Yaokawa, Yasushi Iwata, Yoshio Sugiyama, Hiroaki Iwahori, Shuxin Dong, Yuichi Furukawa
  • Patent number: 8627875
    Abstract: This invention teaches an improved apparatus and method to make metal alloy castings, such as freight car yokes. One embodiment of the invention comprises a core mold assembly unit, wherein the mold unit is filled with molten metal. The core mold assembly units may be further formed of the same material, such as phenolic urethane impregnated sand, which is used to accurately replicate the desired shape of a final desired product.
    Type: Grant
    Filed: July 16, 2009
    Date of Patent: January 14, 2014
    Assignee: Columbus Steel Castings Company
    Inventors: Steven R. Pinkstock, Craig A. Holman, Ronald A. Poe
  • Patent number: 8418744
    Abstract: A molten metal casting die having a modified surface, a method for making such dies, and a method for making articles of manufacture from such dies is disclosed. The methods are designed to protect die steel surfaces having a protective coating from corrosion by molten metals substantially containing liquid copper.
    Type: Grant
    Filed: March 24, 2010
    Date of Patent: April 16, 2013
    Assignee: Nonferrous Materials Technology Development Centre
    Inventors: Krishnamurty Balasubramanian, Radha Madhab Mohanty
  • Patent number: 8403026
    Abstract: A rotor for an induction motor and a method of preparing same. The method includes making a squirrel-cage rotor made up of a cage and a laminate stack by forming a mold around the stack, heating the stack and introducing a molten metal into the mold such that the molten metal substantially fills a space defined in the stack that corresponds to the cage. In one form, the space includes slots or related channels formed in the stack that upon filling with the molten metal become longitudinal bars that form electric current loops with end rings of the cage. By heating the stack and maintaining it at a temperature high enough to keep the molten metal in a substantially molten state at least long enough for it to flow through the slots of the stack, premature freezing of the molten metal is avoided. In addition, by providing low pressure to the molten metal in conjunction with the elevated temperature in the stack, flow is promoted to ensure a substantially porosity-free, fully dense squirrel-cage for the rotor.
    Type: Grant
    Filed: March 24, 2009
    Date of Patent: March 26, 2013
    Assignee: GM Global Technology Operations LLC
    Inventors: Mark A. Osborne, Barry L. Priem, Dale A. Gerard
  • Patent number: 8387683
    Abstract: The present invention provides a structure for producing cast articles containing one or more inorganic particles selected from amorphous and artificial graphites, an inorganic fiber and a thermosetting resin and having a gas permeability of 1 to 500.
    Type: Grant
    Filed: January 15, 2009
    Date of Patent: March 5, 2013
    Assignee: Kao Corporation
    Inventors: Akira Yoshida, Masayuki Osaki, Toshiki Matsuo, Tomofumi Kanzawa
  • Patent number: 8376024
    Abstract: Tubular metal articles such as pipe and cylinder liners are produced by centrifugal casting on a permanent metal mold coated by refractory glass on the active surface. A coating suspension mix is evenly distributed onto the mold to form a uniform layer of insulation on the surface of the mold. The material for the coating comprises of essentially a waterborne suspension mix of glass particles. The suspension is given time to dry on the surface of the mold. The glass particles dispersed in the suspension are both non-crystalline and nonporous. The glass particles in the suspension and forming the coating are not dissolved and do not chemically attract the polar water molecule or cause it to bond to the surface of glass in the suspension or to the mold active surface. Articles cast as such are smooth surfaced and require only limited machining.
    Type: Grant
    Filed: December 31, 2011
    Date of Patent: February 19, 2013
    Inventor: Charles Earl Bates
  • Patent number: 8327909
    Abstract: A method for the casting of cast parts from an iron melt forming vermicular or spheroidal graphite, includes casting iron melt into a casting mold, which includes at least one casting mold part, which is formed from a mold material, which is mixed from a sand-type basic material and an organic binder, and then gassed with a gas containing sulphur in order to harden the binder, such that a mold part of stable form is obtained. The method provides embodiments in which molds produced in accordance with the SO2 process enable the risk of occurrence of local microstructure degeneration in the cast part to be reduced to a minimum. This is achieved in that, after the hardening of the mold part and before the casting, at least one of the surfaces, which comes into contact with the iron melt, is provided with a coating containing a non-volatile sulphide former.
    Type: Grant
    Filed: July 4, 2008
    Date of Patent: December 11, 2012
    Assignee: Fritz Winter Eisengiesserei GmbH & Co. KG
    Inventor: Jörg Knechten
  • Publication number: 20120308430
    Abstract: The present invention provides a sealing ring and a preparation method thereof. The sealing ring, based on percent by weight, includes 80%-85% of aluminum, 10%-15% of titanium, 0.1%-1% of scrap iron, and 4%-4.9% of potassium fluoroaluminate. Moreover, the present invention provides a method for preparing sealing ring, which includes the following steps: Step A: melting the aluminum in a medium-frequency induction furnace, adding the potassium fluoroaluminate to the medium-frequency induction furnace after melting the aluminum, melting and stirring the mixture evenly; Step B: adding titanium scrap or sponge titanium, and scrap iron to the mixture successively, melting and mixing the mixture totally at 800° C. to 1200° C., standing the mixture after stirring evenly; Step C: removing scum on the surface; Step D: casting into a mould to obtain a final sealing ring.
    Type: Application
    Filed: August 14, 2012
    Publication date: December 6, 2012
    Applicant: Shenzhen Sunxing Light Alloys Materials Co., Ltd.
    Inventors: Xuemin CHEN, Qingdong YE, Jimin YUAN, Liping HU, Ming YIN
  • Patent number: 8205659
    Abstract: The invention concerns a metal, iron-containing permanent mold, in particular a permanent mold made of steel, which can be subjected to a liquid or flowable aluminum material, and in which a coating for protecting the permanent mold and for achieving an optimal casting result can be produced using a mold release agent. The invention additionally concerns a mold release agent for producing such a coating, and a method for producing such a coating.
    Type: Grant
    Filed: September 7, 2006
    Date of Patent: June 26, 2012
    Assignee: KS Aluminium-Technologie GmbH
    Inventor: Manfred Laudenklos
  • Publication number: 20120126092
    Abstract: The present invention relates to a refractory coating for producing mold coatings by application to inorganically or organically-bound molding materials in lost molds or to cores for iron and steel casting, wherein the ready-to-use refractory coating has proportion by weight of 0.001% or more and less than 1% of inorganic hollow bodies, which partially or fully consist of crystalline material and have a softening point of 1000° C. or higher.
    Type: Application
    Filed: April 21, 2010
    Publication date: May 24, 2012
    Applicant: HUTTENES-ALBERTUS CHEMISCHE WERKE GmbH
    Inventor: Andreas JATTKE
  • Patent number: 8016019
    Abstract: The object of the present invention is to provide a casting method capable of simultaneously attaining the shortening of cycle time and the improvement in casting quality. The pressure allowing the molten metal level to go up to the positions of from P0 to P4 is applied to the molten metal within a molten metal reservoir 1. Then, the pressure of P4 is maintained for a predetermined time. During this time, the molten metal which comes into contact with an upper die 4 is cooled earlier than the molten metal being in contact with another die. Through this cooling the molten metal shrinks. However, since the pressure of P4 is maintained, the molten metal is supplied from the lower side to a shrunk portion, so as not to cause shrinkage cavity or underfill.
    Type: Grant
    Filed: April 17, 2008
    Date of Patent: September 13, 2011
    Assignee: Honda Motor Co., Ltd.
    Inventors: Kiyoshi Shibata, Toshirou Ichihara, Keizou Tanoue, Kouzou Miyamoto, Masamitsu Yamashita
  • Patent number: 8011419
    Abstract: Thermal expansion defects, i.e. veining, are reduced in iron, steel, and nonferrous castings by adding a lithia-containing material in a sufficient amount to the silica sand mold. Adjusting current formulations to maximize the use of lesser expensive raw materials and minimize the use of more expensive raw materials to lower the overall percentages of lithia/metallic oxide containing additives while still reducing or eliminating thermal expansion related defects in the metal casting process reduces the overall cost to manufacture the product.
    Type: Grant
    Filed: October 1, 2008
    Date of Patent: September 6, 2011
    Assignee: IGC Technologies, LLC
    Inventors: Jeffrey Jon Cieplewski, Andrew Callan, Rebecca Roti
  • Patent number: 8007580
    Abstract: An additive to foundry sand molding and core aggregates is used to produce sand cores and molds comprising kyanite, spodumene, titanium dioxide, ilmenite and black iron oxide. The additive produces a sand-based foundry molding and core aggregate which resists the formation of some of the defects commonly associated with the production of castings produced by silica sand-based molding and core aggregates. In particular, the additive improves the quality of castings poured at temperatures higher than those of the pouring temperatures of molten iron, such as in steel castings, and in iron castings with “hot spots.
    Type: Grant
    Filed: November 6, 2008
    Date of Patent: August 30, 2011
    Assignee: IGC Technologies, LLC
    Inventors: Jeffrey J. Cieplewski, Andrew Callan, Rebecca Roti
  • Patent number: 7896061
    Abstract: The objective of the present invention is to provide a product that is superior in barrier properties (for example, zinc erosion resistance and anti-adhesive property), abrasion resistant property, surface hardening property, thermal stability and life-time prolonging property. The product, which is made in direct contact with molten metal containing zinc in a molten state, is characterized by including an iron-tungsten alloy coating that is applied to a part or the whole of the surface of the product that comes directly in contact with the molten metal.
    Type: Grant
    Filed: February 1, 2006
    Date of Patent: March 1, 2011
    Assignees: Nomura Plating Co., Ltd., Osaka Prefectural Government
    Inventors: Keiji Nakai, Tokumi Ikeda, Takahiro Hamada, Tsutomu Morikawa, Takashi Nishimura, Takuo Nakade
  • Publication number: 20100307714
    Abstract: The present invention provides a structure for producing cast articles containing one or more inorganic particles selected from amorphous and artificial graphites, an inorganic fiber and a thermosetting resin and having a gas permeability of 1 to 500.
    Type: Application
    Filed: January 15, 2009
    Publication date: December 9, 2010
    Inventors: Akira Yoshida, Masayuki Osaki, Toshiki Matsuo, Tomofumi Kanzawa
  • Publication number: 20100290946
    Abstract: The invention relates to methods of making articles of semiconducting material on a mold comprising semiconducting material and semiconducting material articles formed thereby, such as articles of semiconducting material that may be useful in making photovoltaic cells.
    Type: Application
    Filed: May 14, 2009
    Publication date: November 18, 2010
    Inventors: Glen Bennett Cook, Christopher Scott Thomas, Natesan Venkataraman
  • Patent number: 7744056
    Abstract: There is provided a hard-material-coated member which is suitable as a long-life mold for plastic working of metals and which has a metal as base material and coating layers formed at least on its working plane by physical vapor deposition. At least three layers, i.e., a layer a) as the outermost layer, a layer c) just above the base material and a layer b) between layer a) and the layer c) are formed as coating layers. The hardness values of these layers in terms of hardness symbol HV 0.025 are as follows: 2500>(the hardness of the layer a)>1000, 3500>(the hardness of the layer b)>2300, 2500>(the hardness of the layer c)>1000, (500+the hardness of the layer a)<(the hardness of the layer b), and (500+the hardness of the layer c)<(the hardness of the layer b); the thickness of the layer b) is smaller than that of the layer c); and the total thickness of the coating layers is 5 to 15 ?m.
    Type: Grant
    Filed: September 25, 2007
    Date of Patent: June 29, 2010
    Assignee: Hitachi Metals, Ltd.
    Inventors: Kenichi Inoue, Fumiaki Honda
  • Patent number: 7723401
    Abstract: This invention relates to a process for making foundry shapes (e.g. cores and molds) using epoxy-acrylate cold-box binders containing an oxidizing agent and elevated levels of an organofunctional silane, which are cured in the presence of sulfur dioxide, and to a process for casting metals using the foundry shapes. The metal parts have fewer casting defects because the foundry shapes made with the binder are more resistant to erosion.
    Type: Grant
    Filed: July 5, 2007
    Date of Patent: May 25, 2010
    Assignee: Ashland Licensing and Intellectual Property, LLC
    Inventors: Xianping Wang, H. Randall Shriver, Jorg Kroker
  • Patent number: 7615095
    Abstract: A powder product for the protection of centrifugal casting molds for cast iron pipes includes an inoculating metal alloy and possibly mineral powders, and a strongly reducing metal that is volatile at the temperature of the liquid cast iron. The use of products according to the invention prevents accumulation of dirt on molds and improves the surface condition of the cast iron pipes.
    Type: Grant
    Filed: January 21, 2003
    Date of Patent: November 10, 2009
    Assignee: Pechiney Electrometallurgie
    Inventor: Thomas Margaria
  • Patent number: 7600556
    Abstract: A method of the surface treatment of a mold for casting, which comprises subjecting a cavity surface of a fixed mold made by the use of a SCM420 material to first shot peening, a sulfurizing-nitriding treatment and second shot peening. The resulting cavity surface of the fixed mold exhibits a high hardness of 700 or higher in terms of Vickers hardness due to the presence of a sulfurized and nitrided layer, and further has a compression residual stress of more than 1200 Mpa and a largest height, which is a surface roughness value defined by JIS standard, of 8 ?m or less.
    Type: Grant
    Filed: October 28, 2003
    Date of Patent: October 13, 2009
    Assignee: Honda Motor Co., Ltd.
    Inventors: Hiroaki Koyama, Yasuhiro Shimamura, Toshihiro Miyauchi, Michiharu Hasegawa, Fumitaka Miyagawa
  • Patent number: 7575042
    Abstract: A method for forming an article is described. The method includes the step of applying a precursor material to at least one surface of a mold structure for casting the article, and curing the applied precursor material. The precursor material includes facecoat-forming constituents which can be curably converted into a facecoat; and a protective coating-former for the article being cast. Molten material is then introduced into the mold structure, so as to come in contact with the facecoat formed from the cured precursor material. The molten material is cooled, to form the article. The cured precursor material, which is in contact with a surface of the cast article, is then reacted with the article, to form the protective coating on the surface of the article. Related mold structures are also described.
    Type: Grant
    Filed: March 30, 2006
    Date of Patent: August 18, 2009
    Assignee: General Electric Company
    Inventors: Bernard Patrick Bewlay, Melvin Robert Jackson
  • Publication number: 20080265626
    Abstract: In a method of making a subframe of a motor vehicle profile elements made of hollow sections of steel are placed in a casting tool. Subsequently, aluminum material is filled into the casting tool to casting around the profile elements so as to form plural cast nodes on the profile elements in spaced-apart relationship.
    Type: Application
    Filed: April 23, 2008
    Publication date: October 30, 2008
    Applicant: Benteler Automobiltechnik GmbH
    Inventors: Jochen Dorr, Michael Wibbeke
  • Publication number: 20080257521
    Abstract: In order to increase the endurance and lifetime of highly loaded components (6, 8, 12, 14, 24, 26, 34) of a steelworks, an electrolytically applied coating (38) is provided, having a ductile metallic base material (39), in particular nickel or a nickel alloy, with hard material particles (40), in particular boron carbide particles, incorporated in it. This measure achieves high resistance to corrosion, good thermal conductivity and at the same time high mechanical loadability.
    Type: Application
    Filed: November 7, 2006
    Publication date: October 23, 2008
    Inventors: Thomas Sontgen, Robert Wagner
  • Patent number: 7347247
    Abstract: A core rod is utilized in the process of forming a core in a metal casting. The core rod has a length and opposite ends. The core rod is generally round in cross-section along at least a portion of the length of the core rod proximate at least one of the ends configured for use in forming the core of the metal casting. The core rod is made from a precipitation-hardenable alloy including about 40.0 to 75.0 wt. % Ni, about 0.0 to 25.0 wt. % Co, about 10.0 to 25.0 wt. % Cr, and about 0.0 to 20.0 wt. % Fe. A method for forming a core within a metal casting includes the steps of providing a precipitation-hardenable alloy core rod having a length and opposite ends; packing sand around at least one end of the core rod to form a sand core with core rod; placing the sand core with core rod into a mold; pouring molten metal into the mold and around the sand core with core rod; and producing a metal casting having a core and a uniform sidewall thickness in a range of +/?0.060 inches.
    Type: Grant
    Filed: May 21, 2007
    Date of Patent: March 25, 2008
    Assignee: Hildreth Manufacturing, LLC
    Inventors: Gerald Scott, Gerald Selan, Terry Hildreth
  • Publication number: 20080000611
    Abstract: Disclosed herein are methods for forming casting molds. In one embodiment, a method for forming a mold comprises casting a mold having a cavity surface, forming surface features on the cavity surface, wherein the surface features comprise a mixture, and heat treating the mixture. In another embodiment an article is disclosed.
    Type: Application
    Filed: June 28, 2006
    Publication date: January 3, 2008
    Inventors: Ronald Scott Bunker, Canan Uslu Hardwicke
  • Patent number: 7302990
    Abstract: A method of forming at least one concavity of a selected size and shape within a surface of an internal passageway of a metallic component comprises: depositing a ceramic-based material by a direct-write technique onto a ceramic core which is suitable for forming the internal passageway during a casting process to form the metallic component, wherein the ceramic-based material is deposited as a positive feature; heat-treating the deposited ceramic-based material; forming the metallic component by a casting process in which the ceramic core is incorporated into the casting, in a position selected as a desired position for the internal passageway; and then removing the ceramic core from the metal component after the casting process is complete, thereby forming the internal passageway, with the concavity contained within the surface of the passageway, said concavity formed by removal of the positive feature of the ceramic-based material.
    Type: Grant
    Filed: May 6, 2004
    Date of Patent: December 4, 2007
    Assignee: General Electric Company
    Inventors: Ronald Scott Bunker, Canan Uslu Hardwicke, Ching-Pang Lee
  • Patent number: 7287573
    Abstract: A green product for use in fabricating a ceramic article comprises a ceramic powder immobilized within a silicone matrix, wherein the silicone matrix comprises one or more cross linked or polymerized silicone monomers and/or oligomers, wherein the one or more cross linked or polymerized silicone monomers and/or oligomers have a alkenyl reactive functional group and a hydride reactive functional group. Processes for forming a green product and a ceramic core with the silicone monomers and/or oligomers are also disclosed.
    Type: Grant
    Filed: September 30, 2003
    Date of Patent: October 30, 2007
    Assignee: General Electric Company
    Inventors: Thomas McNulty, John Leman
  • Patent number: 7234507
    Abstract: A die coating for use on the surface of a metal mold or die component contacted by molten metal in low pressure or gravity die casting, and a method for its production. The die coating includes a porous layer of ceramic material produced by co-deposition, using a thermal spraying procedure, of a powder of said ceramic material and a powder of an organic polymer material. After the co-deposition, the co-deposited layer is heated to remove the polymer material, and provide the porous layer of ceramic material.
    Type: Grant
    Filed: January 2, 2004
    Date of Patent: June 26, 2007
    Assignee: Cast Centre Pty Ltd., Department of Mining, Minerals and Materials, Engineering, University of Queensland
    Inventors: Mahnaz Jahedi, Mary Giannos, Stefan Gulizia
  • Patent number: 7225856
    Abstract: A core rod is utilized in the process of forming a core in a metal casting. The core rod has a length and opposite ends The core rod is generally round in cross-section along at least a portion of the length of the core rod proximate at least one of the ends configured for use in forming the core of the metal casting. The core rod is made from a precipitation-hardenable alloy including about 40.0 to 75.0 wt. % Ni, about 0.0 to 25.0 wt. % Co, about 10.0 to 25.0 wt. % Cr, and about 0.0 to 20.0 wt. % Fe. A method for forming a core within a metal casting includes the steps of providing a precipitation-hardenable alloy core rod having a length and opposite ends; packing sand around at least one end of the core rod to form a sand core with core rod; placing the sand core with core rod into a mold; pouring molten metal into the mold and around the sand core with core rod; and producing a metal casting having a core and a uniform sidewall thickness in a range of +/?0.060 inches.
    Type: Grant
    Filed: August 4, 2003
    Date of Patent: June 5, 2007
    Assignee: Hildreth Manufacturing, LLC
    Inventors: Gerald Scott, Gerald Selan, Terry Hildreth
  • Patent number: 7222657
    Abstract: A metal object is formed by die-casting with the use of a specially treated mold. The mold has cavity-defining surfaces covered by a heat-insulating layer made of a material that includes ceramic powder and heat-resistant resin. Molten metal is injected into the cavity coated with the heat-insulating layer.
    Type: Grant
    Filed: January 9, 2003
    Date of Patent: May 29, 2007
    Assignee: Fujitsu Limited
    Inventors: Koichi Kimura, Kota Nishii
  • Patent number: 7159640
    Abstract: A casting member comprising hot-die steel or high-speed steel as base material and having coating layers at least on its working plane, wherein the outermost layer among the coating layers consists essentially of at least one nitride, oxinitride or carnonitride composed mainly of V, and another coating layer comprising at least one nitride, oxinitride or carnonitride composed mainly of Cr is formed as a layer just above the base material. If necessary, an intermediate layer comprising at least one nitride, oxinitride or carnonitride composed mainly of V and Cr may be formed as a coating layer on the boundary surface between the outermost layer and the layer just above the base material. The thickness of the outermost layer is preferably 0.5 to 5.0 ?m, the thickness of the layer just above the base material is preferably 0.5 to 3.0 ?m, and the thickness of the intermediate layer is preferably 1.0 ?m or less.
    Type: Grant
    Filed: August 8, 2005
    Date of Patent: January 9, 2007
    Assignee: Hitachi Metals, Ltd.
    Inventors: Kenichi Inoue, Ken Inoue
  • Patent number: 7096921
    Abstract: The present invention provides coating systems that minimize thermal and residual stresses to create a fatigue- and soldering-resistant coating for aluminum die casting dies. The coating systems include at least three layers. The outer layer is an alumina- or boro-carbide-based outer layer that has superior non-wettability characteristics with molten aluminum coupled with oxidation and wear resistance. A functionally-graded intermediate layer or “interlayer” enhances the erosive wear, toughness, and corrosion resistance of the die. A thin adhesion layer of reactive metal is used between the die substrate and the interlayer to increase adhesion of the coating system to the die surface.
    Type: Grant
    Filed: May 23, 2005
    Date of Patent: August 29, 2006
    Assignee: Colorado School of Mines
    Inventors: John J. Moore, Dalong Zhong
  • Patent number: 7081487
    Abstract: This invention relates to foundry binder systems, which cure in the presence of sulfur dioxide and an oxidizing agent, comprising (a) an epoxy resin; (b) an ester of a fatty acid; (c) an effective amount of a oxidizing agent, and (d) no ethylenically unsaturated monomer or polymer. The foundry binder systems are used for making foundry mixes. The foundry mixes are used to make foundry shapes (such as cores and molds) which are used to make metal castings, particularly ferrous castings.
    Type: Grant
    Filed: July 25, 2003
    Date of Patent: July 25, 2006
    Assignee: Ashland Licensing and Intellectual Property LLC
    Inventor: H. Randall Shriver
  • Patent number: 7066234
    Abstract: A simple, cost-effective stamping or molding in the nanometer range is enabled using a stamping surface or molding face with a surface layer having hollow chambers that have been formed by anodic oxidation.
    Type: Grant
    Filed: October 28, 2002
    Date of Patent: June 27, 2006
    Assignee: AlCove Surfaces GmbH
    Inventor: Thomas Sawitowski
  • Patent number: 7055574
    Abstract: The present application relates to a method of producing a metal article having an internal passage coated with a ceramic coating. The method comprises: preparing a core for defining the internal passage; applying the ceramic coating on the core; assembling the core with the ceramic coating applied thereon into a mold; casting metal into the mold at a pour temperature lower than the melting temperature of the ceramic coating; and removing the core. The ceramic coating may be applied by plasma spraying or slurry deposition.
    Type: Grant
    Filed: July 27, 2004
    Date of Patent: June 6, 2006
    Assignee: Honeywell International Inc.
    Inventors: Thomas E. Strangman, Udo K. Schuelke
  • Patent number: 6997235
    Abstract: A plasticizing barrel for a plastics processing machine includes a body having a hollow cylindrical configuration and defining an axis; and a coating formed on an inner wall surface of the body and including at least one groove extending in axial direction of the body. The coating, e.g., a wear-resisting protective layer, may be produced through centrifugal casting, whereby the grooves are formed by projections of a negative mold inserted in the hollow-cylindrical body.
    Type: Grant
    Filed: February 10, 2003
    Date of Patent: February 14, 2006
    Assignee: Krauss-Maffei Kunststofftechnik GmbH
    Inventors: Michael Zelleröhr, Martin Würtele
  • Patent number: 6957489
    Abstract: The aim of the invention is to produce a light-alloy bearing bush with a rough external surface. To achieve this, particles, which are subsequently surrounded in part by the molten metal, are applied to the surface of the casting mould. When the bearing bush is released from the mould, the particles remain in said bush and are subsequently removed from the bearing bush preform either mechanically or by being dissolved in liquid.
    Type: Grant
    Filed: June 7, 2002
    Date of Patent: October 25, 2005
    Assignee: Mahle GmbH
    Inventors: Karlheinz Bing, Martin Rühle, Fritz Warth, Frank Winger
  • Patent number: RE43694
    Abstract: A simple, cost-effective stamping or molding in the nanometer range is enabled using a stamping surface or molding face with a surface layer having hollow chambers that have been formed by anodic oxidation.
    Type: Grant
    Filed: June 26, 2008
    Date of Patent: October 2, 2012
    Assignee: Sharp Kabushiki Kaisha
    Inventor: Thomas Sawitowski