Abstract: A high melting temperature metal, casting mold is made of sheet metal embedded in a supporting mass of refractory particles preventing deformation of the sheet metal under the weight of the cast metal and conducting heat from the sheet metal at a rate preventing complete melting of the sheet metal.

Abstract: Method and apparatus for casting a metal article in a mold at least as long as the article, utilizing a cooled mold of elongated form having top and bottom portions. The method includes the steps of introducing molten metal from a source through the bottom portion of the mold, flowing molten metal into the mold so as to form a solidifying casting shell which during casting occupies at least 40% of the cross-sectional mold area and has a molten core, and flowing molten metal from the source through the core towards the mold top.

Abstract: A porous high-silica core is disclosed for use in directional solidification casting processes having exceptional thermal stability at temperatures above 1650.degree. C. and containing mineralizers which promote the formation of cristobalite. The cores may be made by mixing at least 75 parts of essentially pure fused silica particles with 1 to 25 parts of activating particles containing a mineralizer, such as an alkali metal or alkaline earth metal compound, may be fired at a temperature of 1000.degree. to 1300.degree. C. until they contain 35 percent or more of cristobalite and may then be cooled to room temperature. They may thereafter be incorporated in a shell mold in accordance with the "lost-wax" process and preheated with the shell mold at a temperature of 1300.degree. to 1600.degree. C. to provide a cristobalite content of 60 to 85 percent or more within a short period of time, such as 10 to 30 minutes, and before a molten superalloy is allowed to flow into the mold.

Abstract: An improved ingot mold for producing steel ingots is disclosed. The primary feature of this improved mold is an interior sidewall coating which is composed of an aqueous slurry of finely divided iron oxide and a lignosulfonate.

Abstract: The crushability of a ceramic article suitable for use in the casting and directional solidification of advanced superalloy materials is enhanced by utilizing a two-phase mixture of material and inducing microcracks in the material. The crushability is further enhanced by forming the article to include a predetermined porosity content.

Abstract: A process for producing a self-curable and water-soluble mold, which comprises admixing a suitable amount of water with a mixture consisting of (A) 100 parts by weight of refractory sand particles composed of alumina, (B) 1 to 5 parts by weight of at least one alkali metal phosphate selected from the group consisting of potassium phosphate and sodium phosphate, and (C) 0.2 to 3 parts by weight of an aluminum powder; shaping the resulting mixture into a mold of the desired form; and then allowing the mold to cure spontaneously.

Abstract: An open type casting mold suitably used for continuously casting metals having a large temperature difference between the melting point and the solidifying point thereof, said casting mold comprising a water-cooling jacket, a 1st stage die portion of other refractory material than graphite inserted in the mold at the inlet portion, said refractory material having a lubricating action with slight abrasion, and a 2nd stage die portion of graphite inserted in the mold at the outlet portion, said 1st stage die portion extending over the back end of the water-cooling jacket into a pouring basin side for a definite length.Better results are obtained by covering the outer surface of the extended portion of the 1st stage die portion with a fixing member of a refractory material, fixing the fixing member of refractory material to the 1st stage die portion by means of a metallic protecting member, and fixing the metallic protecting member to the water-cooling jacket.

Abstract: An improved graphite mold for and process of continuously casting metal wherein the interstitial space in the mold is impregnated with an unsaturated oil, or mixture of unsaturated oils, having a drying capability equivalent to at least soybean oil. Heat is applied to dry the oil, and subsequently metal is cast in the mold thereby carbonizing the oil or mixtures thereof in the interstitial space.

Abstract: In the casting of metal alloys to form hollow articles, a mold of a desired shape containing a core material fabricated to a desired configuration from a silicon yttrium or silicon lanthanide oxynitride is filled with a molten metal alloy while maintaining the mold under a vacuum or under a blanket of an inert gas after which the mold is allowed to cool slowly to room temperature. The casted metal alloy with the core material exposed at one end is removed from the mold and heated under ambient conditions, thereby causing the silicon yttrium or silicon lanthanide oxynitride to oxidize with a large volume expansion and a concomitant catastrophic failure of the core material. The broken pieces of core material are removed from the casting which has a smooth inner surface, an indication that no chemical reactions have occurred between the alloy and the core material.

Abstract: In preparation of a mold for metal casting, a thermosetting resin layer, preferably of a thickness in a range from 2 to 100 micrometers, is formed between the refractory filler in the molding box and a covering laminate such as a thermoplastic synthetic resin film for tightly covering the filler surface so that the thermosetting resin layer develops, during metal casting, a shell layer for reinforcing the cavity wall of the mold due to heat given by molten metal. Development of casting defects such as sand marks and blow holes and occurrence of mold crumbling can effectively be prevented by the presence of the shell layer.

Abstract: In a method for casting metal alloys, a molten metal alloy is introduced into a mold of a desired configuration containing a core material fabricated to a desired shape from titanium nitride while maintaining the mold under a vacuum. After allowing the mold to cool slowly to room temperature, the casted metal alloy with the core material exposed at one end is removed from the mold and immersed in a boiling caustic solution, thereby causing the titanium nitride core material to decompose. The casting so obtained has a smooth inner surface, an indication that no chemical reactions have occurred between the alloy and the core material.

Abstract: A copper or copper alloy mold for continuously casting steel is characterized in that the mold has a first layer formed on its interior surface and comprising at least one of nickel and cobalt and a second layer formed on the first layer and containing at least one of nickel and cobalt as a main component and at least one of phosphorus and boron.

Abstract: The present invention is directed to a mold containing an improved core for use in casting hollow, metallic articles. The core is formed of, or covered with, a layer of cellular material which possesses sufficient strength to maintain its structural integrity during casting, but will crush to alleviate the internal stresses that build up if the normal contraction during solidification and cooling is restricted.

Abstract: At least one element of a superalloy cast into a refractory oxide-silica investment mold is oxidized to form a metal oxide barrier layer at the mold-metal interface to permit directional solidification of the cast superalloy at elevated temperatures without metal-mold reaction.

Abstract: A belt-type metal-casting machine comprises a metallic casting belt, preferably of steel, having its side turned toward the melt formed with a heat-lagging (thermal-insulating) layer upon which at least one abrasion-resistant cover layer is applied. The cover layer consists of one or more metals whose fusion temperature or melting point in Kelvin .degree. is equal to or greater than 0.7 times the melting temperature, in .degree.K, of the casting metal to be applied.

Abstract: In an iron molding process and in a mold for carrying out the process, in which the mold is at least locally coated with tellurium or bismuth to promote the production of a white iron structure there is included in the coating a water-bearing substance in which the water is loosely chemically combined tightly enough so that it withstands the heat involved in drying of the mold but is liberated on contact with the molten iron.

Abstract: A mold for the continuous casting of metals, in which at least its inner part is made of a refractory material chosen from the group of materials comprising tantalum, niobium, tantalum-base alloys and niobium-base alloys.

Abstract: This invention is directed to the use of tungsten base alloys containing about 1 to 12 weight percent nickel, about 0.5 to 8 weight percent iron and about 0.5 to about 25 percent molybdenum and at least one additional additive selected from cobalt, chromium, manganese, vanadium, tantalum, zirconium, titanium, yttrium, rhenium, boron, and silicon. Chromium may substitute for molybdenum up to 15%. In addition to being useful for high density applications, structural applications, and high temperature applications, the alloys may be used for die casting dies, molds, cores and other metal shaping members.

Abstract: The present invention provides a method and apparatus for powder metal formation in which a plated shell is formed corresponding to the appropriate calculated pre press size of the final part being formed; the electroplate shell is filled with powder metal to be formed; the shell is surrounded by a pressure transferring support media and compacted using a suitable force transmitter such as an isostatic press; and the support media is removed leaving the final product within the electroplate shell which may or may not be removed as desired.

Abstract: Molten metal is mold or die cast by contacting the molten metal-contacting surface of the mold or die with a die lubricant or parting agent in the vapor form and in the substantial absence of added liquid lubricant or parting agent prior to introducing the molten metal into contact with the mold or die surface. The contacting of the molten metal-contacting surface of the mold or die with the vaporous lubricant or parting agent is carried out under conditions such that the vaporous lubricant or parting agent applied to or contacting the molten metal-contacting surface of the mold or die undergoes thermal decomposition thereon. The mold or die surface may be a metal or graphite surface and the applied vaporous lubricant or parting agent may be a normally liquid, thermally decomposable organic compound, such as an alkyl phosphate or an aryl phosphate, e.g., tributyl phosphate and tricresyl phosphate.

Abstract: A contact adhesive that is a polymeric material with a major proportion of a tackifier is applied to sand in making a foundry mold. No curing step for the adhesive is required but instead pressure is applied to get the desired bonding together of the sand granules.

Abstract: A method of forming a metal oxide barrier layer at the interface between a refractory oxide-silica investment mold and a contained metal superalloy includes the firing of the mold or the mold-metal system, in a controlled prevailing atmosphere having a predetermined amount of oxygen therein. The barrier layer enables directional solidification of the contained superalloy at elevated temperatures to occur without metal-mold reaction.

Abstract: The surface quality of bottom poured ingots can be improved by placing on the mould floor, prior to pouring, a bonded composition of one or more fluxing agents and expandable graphite.