Abstract: Aspects of the disclosure generally relate to a casting mold for forming a cast part. The casting mold includes a casting shell having an internal surface bounding an interior, and a casting core positioned within the interior to define a cavity between the casting core and the casting shell, whereby the internal surface of the casting shell defines an outer surface of the cast part.

Abstract: A core molding machine which can be made smaller while having a favorable core sand filling property is provided. The machine comprises a core box having a pair of laterally separable dies and a sand filling device, having a blow head disposed under the core box, for filling the core box with core sand directed upward from the blow head; the blow head having a sand blow chamber for guiding the core sand to the core box while being connected to the core box and a sand storage chamber communicating with the sand blow chamber; the sand filling device having a compressed air supply unit for supplying a compressed air for blowing the core sand into the core box and an aeration air supply unit for supplying an aeration air for floating and fluidizing the core sand within the sand blow chamber.

Abstract: The core sand filling device includes the core box, a blow head which is placed below the core box so as to move up and down in a relative manner to the core box and divided into a sand blowing chamber and a sand storage chamber that are communicatively connected to each other, a compressed air supply unit which is communicatively connected to the sand storage chamber and supplies compressed air into the sand storage chamber, an aeration air supply unit which is communicatively connected to the sand blowing chamber and supplies into the sand blowing chamber aeration air for suspending and fluidizing core sand inside the sand blowing chamber, and an exhaust valve which is communicatively connected to the sand blowing chamber and exhausts compressed air remaining in the sand blowing chamber.

Abstract: A molding machine which allows a simplification of a sand filling operation, and the prevention of the formation of a bridge and an air channel in the sand tank, so that the sand filling operation of the molding machine is able to be performed steadily. The molding machine of the present invention includes: a sand tank for storing molding sand to be introduced to a molding flask; a pair of upper and lower sand filling nozzles to guide the molding sand in a horizontal direction, where the molding sand is supplied from a pair of upper and lower sand introducing parts which are located at the lower part of the sand tank; and at least one filter part with a plurality of air-injecting apertures on its entire body, which is attached to at least the entire inner surfaces of the pair of sand introducing parts; wherein the molding sand is fluidized by air injected through the air-injecting apertures of the filter part, and introduced to the molding flask through the sand filling nozzles.

Abstract: The present invention provides a method for green sand molding that prevents a bad casting by producing a mold that does not have a brittle surface. The method has the steps of filling the green sand into a flask while fluidizing the green sand by aeration at a pressure between 0.05 and 0.18 MPa, and squeezing the green sand that has been filled in the flask, wherein a mold is produced so that the friability of the mold is 10 or less. The friability is calculated by the following steps: putting the mold in a rotating cylindrical sieve that has a diameter of 177.8 min and. USA, sieve size No. 8, rotating the cylindrical sieve at 57 rpm for 60 seconds, dividing the weight of the sand that has passed through the sieve by the weight of the sand and multiplying the quotient by 100.

Abstract: Disclosed is a molding machine for simultaneously making upper and lower molds with cope and drag flasks, a matchplate, upper and lower squeezing boards, and a lower filling frame. This machine also includes a cylinder for raising and lowering the lower squeezing board, a driving mechanism that includes pneumatic and hydraulic piping systems for driving the cylinder using an air-on-oil system, and a controller for controlling the driving mechanism. The drag flask, the matchplate, the filling frame, and the lower board define a lower molding space, while the matchplate, the upper board, and the cope flask define an upper molding space such that the controller controls the driving mechanism to drive the cylinder at a low pressure. The lower squeezing board is raised to squeeze the molding sand for simultaneously making the two molds such that the controller controls the driving mechanism to drive the cylinder at a high pressure.

Abstract: The present invention is to provide a machine and a method for suctioning and exhausting air from a storage tank for sand in a molding machine that has less on-off valves and prevents sand from adhering to the interior of the valve for exhausting air while the air is being exhausted.

Abstract: A flaskless molding method, wherein a match plate (5) is held between an upper flask (2) and a lower flask (3) and squeeze plates (6) and (7) are inserted into the openings of the upper flask (2) and the lower flask (3) to form an upper manufacturing space and a lower manufacturing space with initial volumes. A foundry sand is filled in the upper and lower manufacturing spaces with the initial volumes through the supply ports of the flask (2) and (3) (first filling). Next, the squeeze plates (6) and (7) are retreated to expand the upper and lower manufacturing spaces more than the initial volumes. The foundry sand is filled again in the expanded upper and lower manufacturing spaces through the supply ports (second filling). After the second filling is completed, the squeeze plates (6) and (7) are advanced to compress the foundry sand in the upper and lower manufacturing spaces so as to manufacture the upper and the lower flasks stacked on each other.

Abstract: To produce moulds or cores for foundry purposes from a mixture (M) of moulding material or sand and a binder, the mixture (M) is shot using a shooting unit (2) or from a shooting tube (3) and a shooting head (4) through at least one discharge opening (7) arranged on a shooting plate (5) into a moulding or core tool (8). The region of the discharge opening (7) is moistened and/or kept moist by a liquid between at least two shooting operations, where the liquid (15) used for moistening is atomized by at least one ultrasonic atomizer (16) to form an aerosol capable of suspension and is fed to the discharge opening (7) directly or indirectly, for example, via one or more lines (18, 23).

Abstract: A cost-effective starch/water-based binder composition and related method for forming silica sand cores and molds for foundries, wherein the sand grains are pre-coated with starch having additives making the coated sand effective for blowing said cores and molds. One or more additives are included with the starch; preferably sodium tripolyphosphate and -silicon or Silres BS16. The preferred starch is a tapioca starch. The binder of the invention is highly competitive due to its low cost and effectiveness for forming silica-sand cores and molds, being particularly effective for use in aluminum foundries for the automotive industry.

Abstract: This invention provides a method for changing a match plate in a molding apparatus for a flaskless upper mold and a lower mold, which method allows easy change of the match plate. This invention is comprised of a first step for moving a existing match plate placed in the apparatus to between a cope flask and a drag flask of one set of flasks in the perpendicular position, and for holding a new match plate between a cope flask and a drag flask of another set of flasks in the horizontal position, a second step for rotating the cope flask and the drag flask holding said existing match plate from the perpendicular position to the horizontal position, and for rotating the other cope flask and the drag flask holding the new match plate from the horizontal position to the perpendicular position, and a third step for moving the new match plate from the perpendicular position to the apparatus, and for moving the existing match plate from the horizontal position to the outside of the apparatus.

Abstract: A method and apparatus for molding molds having no flask wherein a match plate having a pattern is put between a pair of an upper and a lower flask having intakes for foundry sand. An upper and a lower molding space are defined by inserting an upper and a lower squeeze device into openings of the pair of the upper and the lower flask having no match plate, and the pair of the upper and the lower flask and the match plate are rotated and moved so that they become perpendicular and then the intakes of the flasks move upward. The upper and the lower molding space are then filled with the foundry sand. The foundry sand in the molding space is squeezed by the squeezing device. The pair of the flasks and the match plate are rotated so that they become horizontal. Then the match plate is removed, the flasks are matched to each other, and the molds are removed from the pair of flasks.

Abstract: A method and apparatus for molding molds having no flask wherein a match plate is put between an upper and a lower flask having intakes for foundry sand. An upper and a lower molding space are defined by inserting an upper and a lower squeeze device into openings of a pair of the upper and the lower flask having no match plate, and a pair of the upper and the lower flask and the match plate are rotated and moved so that they become perpendicular, and are moved so that the intakes of the flasks move upward. The upper and the lower molding space are filled with the foundry sand. The foundry sand in the molding spaces is squeezed by the squeeze devices. A pair of the flasks and the match plate are rotated so that they become horizontal. Then the match plate is removed. While the preceding processes are being carried out, if necessary a core can be installed between the molds, the flasks are matched to each other, and the molds are removed from the pair of flasks.

Abstract: To produce moulds or cores for foundry purposes from a mixture (M) of moulding material or sand and a binder, the mixture (M) is shot using a shooting unit (2) or from a shooting tube (3) and a shooting head (4) through at least one discharge opening (7) arranged on a shooting plate (5) into a moulding or core tool (8). The region of the discharge opening (7) is moistened and/or kept moist by a liquid between at least two shooting operations, where the liquid (15) used for moistening is atomized by at least one ultrasonic atomizer (16) to form an aerosol capable of suspension and is fed to the discharge opening (7) directly or indirectly, for example, via one or more lines (18, 23).

Abstract: Procedure for the production of sleeves for mini-deadheads and an economical method of casting incorporating the use of said sleeves. A fluoride-free mixture, consisting of microspheres of aluminium silicate, an oxidizable metal, such as powdered aluminium, an oxidizable agent, magnesium as initiator element of the exothermic reaction, are introduced by blowing in a mould fitted with two cores to produce a sleeve provided with two openings, one of which is closed with a plug before being used.

Abstract: A cost-effective starch/water-based binder composition and related method for forming silica sand cores and molds for foundries, wherein the sand grains are pre-coated with starch having additives making the coated sand effective for blowing said cores and molds. One or more additives are included with the starch; preferably sodium tripolyphosphate and silicon or Silres BS16. The preferred starch is a tapioca starch. The binder of the invention is highly competitive due to its low cost and effectiveness for forming silica-sand cores and molds, being particularly effective for use in aluminum foundries for the automotive industry.

Abstract: In a casting mold making system for blowing and packing casting sand accommodated in a receiver of a blow head into a cavity in molding dies by feeding pressurized gas into the receiver, the pressure of pressurized gas to be fed into the receiver is discontinuously raised at least once in the course of feeding of pressurized gas into the receiver.

Abstract: The present invention relates to A method and apparatus for making a sand core (112) utilizing purge air through a core box (100 and 100?) to harden the binder in the sand core (112) proximate the ejection pins (106 and 106?). The sand core (112) may be removed from the core box (100 and 100?) prior to drying the binder completely thereby resulting in an improved production rate of the sand core (112).

Abstract: The invention relates to a method for the manufacture of mould parts, in particular of casting cores, for casting moulds for the casting of molten metal heats, wherein, in a shoot-moulding machine (1), with the aid of filling elements, such as shooting nozzles (8) and a shooting hood (6), material mould (F) containing an inorganic binding agent is filled into a cavity (12) of a mould tool (10) which determines the shape of the mould part (K) which is to be manufactured, wherein, heat is supplied to the mould material (F) filled into the mould tool (10), over a hardening period, in order for the mould material (F) to solidify due to the extraction of moisture, and wherein, during the hardening period, at least the filling elements (6,8) of the shoot-moulding machine (1), which contains mould material (F), and which are in a stand-by position during this hardening period, and are heated concomitantly by the radiant heat emitted by the mould tool (10), are kept at a moisture content level which prevents the soli

Abstract: An apparatus for introducing molding sand into a mold space defined by a pattern plate (1) having a pattern, a flask (2) placed on the pattern plate (1) for surrounding the pattern, and a filling frame (3) placed on the flask (2) and for compacting the molding sand in the mold space. The apparatus includes a sand hopper (10) having an inlet pipe (7) for introducing a first airflow at a low pressure (0.05 to 0.18 MPa) and compressed air thereinto from an upper part thereof, and a plurality of separated nozzles (17) at a lower portion thereof for blowing and introducing the molding sand held in the sand hopper into the mold space by the first airflow. First and second chambers (11 and 12) supply a second airflow under a low pressure (0.05 to 0.18 MPa) and compressed air to the molding sand in the sand hopper (10) to fluidize the molding sand.

Abstract: A system for the spray forming manufacturing of near-net-shape molds, dies and related toolings, wherein liquid material such as molten metal, metallic alloys, or polymers are atomized into fine droplets by a high temperature, high velocity gas and deposited onto a pattern. Quenching of the in-flight atomized droplets provides a heat sink, thereby allowing undercooled and partially solidified droplets to be formed in-flight. Composites can be formed by combining the atomized droplets with solid particles such as powders, whiskers or fibers.

Abstract: In a mould forming machine comprising a moulding chamber, a movable squeeze plate and a pattern, the filling of selected parts of the pattern with compressible mould material is improved by applying vacuum to said selected parts. By applying the vacuum separately to different parts of the pattern at different periods, of time during the filling step, the vacuum application can be applied during shorter periods only when needed, thereby reducing the drying out of the mould material and reducing the amounts of air to be removed by the vacuum system.

Abstract: The present invention relates to a method and apparatus for making a sand mold (112) utilizing reverse purge air through a core box (100 and 100′) to harden the binder in the sand mold (112) proximate the ejection pins (106 and 106′). The sand mold (112) may be removed from the core box (100 and 100′) prior to drying the binder completely.

Abstract: The present invention relates to a method and apparatus for making a sand mold (112) utilizing reverse purge air through a core box (100 and 100′) to harden the binder in the sand mold (112) proximate the ejection pins (106 and 106′). The sand mold (112) may be removed from the core box (100 and 100′) prior to drying the binder completely.

Abstract: A method for producing casting molds, such as cores or core assemblies used in foundry practice, wherein molding material, preferably molding sand, is injected or shot into a molding chamber via a gaseous flow medium, preferably air, under a predeterminable pressure. The shot and resulting solidified mold is deaerated, then the tool is opened, and the solidified mold is removed. The shooting process and/or deaeration process are controlled via detected and, if need be, prepared process parameters according to a predeterminable specification.

Abstract: An apparatus for introducing molding sand into a mold space defined by a pattern plate (1) having a pattern, a flask (2) placed on the pattern plate (1) for surrounding the pattern, and a filling frame (3) placed on the flask (2) and for compacting the molding sand in the mold space. The apparatus includes a sand hopper (10) having an inlet pipe (7) for introducing a first airflow at a low pressure (0.05 to 0.18 MPa) and compressed air thereinto from an upper part thereof, and a plurality of separated nozzles (17) at a lower portion thereof for blowing and introducing the molding sand held in the sand hopper into the mold space by the first airflow. First and second chambers (11 and 12) supply a second airflow under a low pressure (0.05 to 0.18 MPa) and compressed air to the molding sand in the sand hopper (10) to fluidize the molding sand.

Abstract: A system for the spray forming manufacturing of near-net-shape molds, dies and related toolings, wherein liquid material such as molten metal, metallic alloys, or polymers are atomized into fine droplets by a high temperature, high velocity gas and deposited onto a pattern. Quenching of the atomized droplets provides a heat sink, thereby allowing undercooled and partially solidified droplets to be formed in-flight. Composites can be formed by combining the atomized droplets with solid particles such as powders, whiskers or fibers.

Abstract: Ceria is used to assure release between a metal workpiece and associated forming tooling in forming operations conducted at temperatures of 1500.degree. F. (816.degree. C.) and above.

Abstract: Before supplying molding sand into the blow head, a blow-in port of the mold-defining device is connected to a blow-off port of the blow head so that molding sand flowing out of the blow-off port is received by the device after the molding sand has been supplied to the blow head. Preferably, after molding sand has been charged into the mold space but before the mold-defining device is moved out of engagement with the blow head, sand remaining in the blow-off port is hardened.

Abstract: A method for spray forming manufacturing of near-net-shape molds, dies and related toolings, wherein liquid material such as molten metal, metallic alloys, or polymers are atomized into fine droplets by a high temperature, high velocity gas and deposited onto a pattern. Quenching of the atomized droplets provides a heat sink, thereby allowing undercooled and partially solidified droplets to be formed in-flight. Composites can be formed by combining the atomized droplets with solid particles such as whiskers or fibers.

Abstract: The core box includes a cavity therein, a vent in fluid communication with the cavity, ejector members, and apparatus coupled to the ejector members for passing a fluid through the vent into the cavity.

Abstract: Ready-to-pour shells or core assemblies produced utilizing at least two in-line core shooting machines (1), each core shooting machine (1) having two, at least slightly differing sets of tools (4), each set comprising an upper tool (2) and a lower tool (3), and identical conveyor plates (5) serving, on the one hand, as the lower tool (3) of the first core shooting machine (1) and, on the other hand, as for transporting the core (6) or the core assembly along a transfer path (7) through the apparatus.

Abstract: The blowing-in of the sand into the mould is continued while the pressure in the mould chamber increases through a maximum mould pressure and the blowing-in is terminated at a predetermined time period subsequent to reaching maximum pressure. This method ensures that the mould chamber will be completely filled independently of its size or shape without having to keep the blowing-in mould sand active for a longer time than absolutely necessary.

Abstract: An apparatus for cleaning shot hoods during the manufacture of casting molds or core packets that are ready for casting, by means of core shooters or shooting stations, preferably in a linear arrangement, the core shooters in each instance incorporating a shot hood (3) that comprises a shot plate (1) and shot nozzles (2), it being possible to uncouple the shot hood (3) from the core shooter and lay it on a pallet (4) or the like with the shot nozzles (2) pointing downward, characterized by a delivery system (5), a transfer station (6), an emptying station (7), a flushing system (8), a drying system (9), an exit station (10), optionally an inspection station, and a removal system (11), the shot hood (3) that has been laid upon the pallet (4) being moveable from the core shooter to the transfer station (6) by means of the delivery system (5), it then being possible to raise it from the pallet (4) by means of a first manipulator (12) and pivot it through approximately 180.degree.

Abstract: Core sand material is received in an enclosed chamber and is forced into the cavity of a mold by compressing the air above the sand material with essentially no mixing of the air and sand material. The air is compressed by a piston which forces a pressure packer plate downwardly above the core sand material which is held in the bottom of the chamber by a specially designed baffle control plate assembly ready to be forced by the compressed air into the mold.

Abstract: A storage hopper retains the mold core material and an outlet member is connected below the hopper for discharging the mold core material into the core shooting head. The outlet member is inserted into the core shooting head and is mounted on a vertically adjustable machine frame such that it may be inserted to various depths within the core shooting head and may also be removed. A shutoff device in the form of a rotating shutter closes the outlet member. A frame supports the outlet member and the storage hopper and vertically adjusts both for immersion within the core shooting head. A displacement measuring sensor detects the vertical position of the vertical adjustment members in relation to the machine frame. In the method the storage hopper is filled with mold core material, the outlet member is positioned over the core shooting head, and the outlet member is immersed within the core shooting head.

Abstract: A mould chamber including at least one pressing plate is filled by blowing mould sand in through a blowing-in tube ascending at high speed, in which at least some of the blowing-in apertures are adapted to blow the sand in substantially transversely to the ascending movement of the blowing-in tube.

Abstract: Sand is charged into a space in a mold flask by a sand feed nozzle provided on the lower end part of a blow head inserted into a sand charge port formed in the top wall of the mold flask. The blow head is further lowered after completion of the charging so as to deeply insert the sand feed nozzle in the sand charge port in order to press the sand in the vicinity of the sand charge port within the mold flask, thereby uniformly compacting the entire sand in the space.

Abstract: An apparatus for filling an open-top foundry flask with discrete refractory particles by pluviation to embed an expendable pattern to form a lost foam casting mold comprises conduits for directing pressurized gas toward the prepositioned pattern within the flask to deflect pluviating particles and thereby promote uniform packing of the particles about the pattern. The conduits comprise compressed air conduits vertically insertable into the flask through the open top thereof for disposition about the pattern and having multiple orifices for directing pressurized air laterally toward the pattern to achieve the desired uniform packing.

Abstract: As in the parent application, a freshly mixed quick-setting sand mix is blown from a blow box into a mold while a plunger moves through the blow box to chase all of the fluidized sand into the mold. Here, the blow box sand cavity is formed by a tube extending downward but leaving an annular gap above the blow plate. The fluidizing air tends to move bottom sand directly through the center exit in the blow plate. With quick setting sand, any residue is blown into a purge pan while the plunger is advanced. With sand that is not quick setting, and without the plunger, nearly all residual sand settles and tends to be the first blown into the mold during the succeeding blow.

Abstract: A core blowing machine receives match plates on a mounting surface so that a sand and bonding agent mixture may be packed about the match plate and exposed to a catalytic gas for forming a mold component. A support surface is disposed beneath the mounting surface. An auxiliary assembly includes an auxiliary mounting surface and an auxiliary support surface in substantially the same spatial relationship as the mounting and support surfaces. A support jack is placed on the auxiliary support surface and is adjusted in length to extend between the auxiliary support surface and a match plate mounted in the auxiliary assembly. Then the suppot jack is placed in a position on the support surface which is similar to the position occupied on the auxiliary support surface and the matching plate is disposed on the mounting surface. Indicia are provided on both the auxiliary support surface and the support surface to aid in placing the support jack in the similar position on the latter surface.

Abstract: In a closed system a shock pressure wave of a burning gas is used for packing granular mold material loosely distributed around a model. Before the shock pressure is produced, the pore volume of the upper layer of the granular material exposed to the pressure is reduced. Through the pore volume reduction, the active surface of the granular material is increased, so that the gas pressure acts on an increased working surface and, consequently, greater mold hardness is achieved.

Abstract: A blow-moulding machine comprises a mixer for mixing refractory particles with a binder and a hardener or the like, a main tank for transporting moulding sand, a booster provided subsequently to said tank, a blast hose, and a blowing nozzle mounted at the tip end of said hose.

Abstract: A refractory shape is molded on a pattern by pouring over the pattern a mixture of two slurries each of which is stable but which together react to gell. The mixture is formed by merging two slurry streams immediately above the pattern.