Abstract: A register system is provided for making molds for metal casting which reduces flaws attributable to parting line shift. This is accomplished by urging the cope mold flask (11) against two fixed stops (50, 52) on the long axis, and one fixed stop (54) on the short axis of the flask. This same register principle is applied in the drag mold making station 18, where the drag flask (15) is urged against two fixed stops (100, 102) on the long axis, and one fixed stop (90) on the short axis of the flask. At the closer station (24), where the mold halves are assembled, they are again urged against two fixed stops (134, 136) on the long axis, and one fixed stop (142) on the short axis of the flasks. Thus the flasks are properly aligned to the patterns at the mold making stations, and again properly aligned to each other at the closer station, so as to eliminate parting line shift problems of the mold halves.

Abstract: Foundry molding system, apparatus and methods are characterized by horizontally reciprocating flask shuttles located beneath and at entry and exit ends of a molding line conveyor which is operative to support horizontally aligned cope and drag flask sets for indexing along the conveyor in abutting relation through a plurality of stations for production of cope and drag molds in the cope and drag flasks, respectively. The entry and exit flash shuttles respectively operate positively to locate and transfer along the conveyor one flask of cope and drag flask sets out of and into alignment with a flask separate/set-on and flask take-off/close to permit set-on and take-off of the other flask at high production rates.

Abstract: A fluidization apparatus is adapted for use with a flask containing a particulate bed, for example, a foundry flask used in lost foam metal casting. The apparatus comprises a reciprocal plenum box defining a plenum having a gas outlet and receivable within the flask such that the plenum outlet registers with a perforated partition supporting the particulate bed within the flask. The plenum outlet is covered by an air filter suitable for removing contaminants from compressed air. The plenum box also carries a resilient seal member located about the plenum outlet. When the box is received in the flask, pneumatic lifts mounted upon the box raise the box to seal the box against the partition. Compressed air admitted to the plenum flows from the plenum outlet through the filter, which removes entrained contaminants that might otherwise plug the partition, and thereafter through the partition to fluidize the particulate bed.

Abstract: In the manufacture of moulds or mould cores, refractory sand, a resin binder and a catalyst are passed into a mixer to form a free-flowing mixture from which the moulds or mould cores are made. As the sand is fed into the mixer it is cooled by contact with an atmospheric gas in liquid or solid state or the cold vapor of such a gas so as to keep the temperature of the sand as it enters the mixer below that at which the resin cures. To enable the sand to be delivered below a chosen temperature from a quarry to a foundry where the sand is used, the sand after quarrying and drying is fluidized by air, an atmospheric gas in liquid or solid state being introduced into the fluidizing air so as to lower its temperature.

Abstract: Disclosed is a system for precisely locating a cambered ceramic core within the cavity of an injection molding die, such as is used to form patterns for lost wax method casting of gas turbine airfoils. A combination of at least two independent sets of locators are used: one set of at least three is fixed and contacts the periphery of the core while the other set of at least two is movable and engages the centerline of the core. The two sets independently limit the various degrees of core freedom and maintain its position during injection molding. The concave side of the core is preferably contacted by the fixed locators since this biases deviations into the convex side of the part from which excess deviant material is more readily moved.

Abstract: A foundry molding system for molding and closing cope and drag molds includes a linear idler molding line conveyor adjacent a cooling conveyor. Short powered sections are provided at each end of the molding line conveyor for set-off from the cooling conveyor to form the assembled cope and drag flasks into horizontally abutting drag and cope sets on the molding line conveyor and for closing and setting on the cooling conveyor the assembled cope and drag molds. Reciprocating index and control means are provided at each end of the molding line conveyor for indexing the sets therealong in abutting relationship. Powered roller detents or locaters are provided along the conveyor to hold the flasks to separate, center and retain the flasks for a variety of operations such as set-down, molding, drag rollover, coring, closing and set-on. The roller detents at the drag rollover are located in the trunnions of the rollover for operation therewith.

Abstract: Disclosed is a rotary-type continuous motion core making machine capable of carrying a number of core mold boxes, each supported on a carrier adapted to move up and down, a sand distributing system adaped to inject a foundry sand mix into each of the core boxes, and a manifold system for distributing curing and purging gases to the core boxes. The machine is capable of completing a core/mold production cycle in a single circle of turret revolution. The vertical movement of the core box carrier, horizontal radial movement of portions of the gas manifold system, and movements of other parts of the machine are generated by the turret rotation and are controlled by a number of stationary contoured cam tracks. Disclosed also is a novel catalyst gas generating system, a core box assembly comtaining ejector pins in the top portion thereof, and a system for collecting and assembling components into a unified core and mold assembly.

Abstract: Method and apparatus are disclosed for cyclically metering charges of a granulated wax-like or resinous material from a bulk supply and feeding such metered charges into a heated, pressurized reservoir. Each charge of the granulated material is fluidized with a stream of air under pressure to insure flow of the granules. The stream of air also serves to pressurize the reservoir and prevent the escape of hot air therefrom. Cooling of the reservoir inlet to prevent agglutination of the granules also is contemplated.

Abstract: Automatic molding apparatus to make flaskless molds from match plate patterns using sand and binder pre-mix and an activator or catalyst includes form boxes having open faces and double wall construction with a continuous chamber between the walls. The inner wall is vented to the chamber to provide a gas flow passage. The apparatus also includes manifolds which clamp over openings in the top and bottom walls for innoculation and pneumatic withdrawal of activating or catalytic-reacting gases such as hot air or carbon dioxide which are innoculated at an innoculation station into the mold box to decrease the hardening time of the sand. The open faces of the mold box are closed by hinge plates or cover plates each rotated by a rack and pinion. The plates are further secured during sand filling by spring-loaded arms bearing against tapered ribs on the hinge plates.

Abstract: The apparatus comprises high pressure injection means for supplying during an accurately adjustable controlled cycle time an accurately adjustable controlled volume of atomized cold set catalyst into a high pressure dry air, nitrogen and/or CO.sub.2 gas stream passing through the core box to cure the resin followed by a continuing air, nitrogen or CO.sub.2 gas purging of the core box. The fumes from the core box are drawn through a natural gas or propane fired fume incinerator wherein an excess air-fuel mixture causes oxidation of the fumes during a controlled temperature and residence time. The fume incinerator operates continuously at a constant temperature under control by an automatic temperature sensor regardless of fume input and includes suction means to prevent back flow of gasses from the incinerator to the core box.