Abstract: A fugitive pattern of an article to be investment cast wherein the pattern includes a plurality of locator embossments disposed in an array to provide a datum reference system by which the pattern can be held and positioned by a manipulator, such as for example a gripper device to a computer controlled robotic device, for assembly with another component of the pattern assembly. The datum embossments are located on a portion of the pattern that will be removed from the final metallic casting made to replicate the pattern. The casting includes integral cast datum embossments thereon by which the casting can be held and positioned.

Abstract: Method of making a shell mold for casting molten metals or alloys involves forming a thermally collapsible, low density reaction injection molded (RIM) thermosetting polyurethane foam pattern having a shape corresponding to the casting to be made. The pattern is formulated to have an aggregate density (pattern outer skin and pattern cellular core) in the range of about 10 to 15 lbs/ft3 and a smooth continuous as-molded surface devoid of surface connected open cells, dimensional stability over a range of temperatures, and ready, ashless burnout from the shell mold formed thereon without cracking the shell mold. The pattern is free of organometallic catalysts that should not be present in the casting of aerospace superalloys, such as nickel and cobalt base superalloys and titanium. The pattern then is invested without the need for any surface polymer or other film or layer in a shell mold.

Abstract: Apparatus for forming a pour hole and main sprue in an investment mold for lost wax casting. A sprue having a flared base, a base member adapted to receive the flared base of the sprue for vertically supporting the sprue, and a flask for containing investment material immersing the sprue, define the casting apparatus of the present invention. The present investment casting sprue apparatus forms a pour hole in the hardened investment material suitable for smoothly introducing liquid metals into the cavity formed by the sprue, thereby reducing the number of casting defects related to turbulent filling. This is accomplished as a result of the flared base of the sprue, which forms a gentle transition into the sprue. The current practice, by contrast, uses a sprue having a cylindrical base which is simply inserted into a hole in a finger or button formed in the supporting base member for the sprue without regard to this smooth transition.

Abstract: A crankshaft casting pattern insert 10 which includes selectively adjustable portions 14, 16, which respectively correspond the front and rear main bearing journal portions of the crankshaft. Each adjustable portion 14, 16 includes a removable insert or member 18, a key member 20, several “vertical” spacers 22, several “lateral” spacers 24, and a fastener 26. Adjustable portions 14, 16 allow the pattern 10 to be selectively modified in shape, effective to compensate for pattern wear and to allow multiple crankshafts to be produced which have a substantially similar balance capability. Pattern 10 may also include several validation pads or points 50 which allow the produced crankshafts to be measured with improved accuracy.

Abstract: A casting includes a heat transfer surface having a plurality of cavities. The plurality of cavities include a density of at least about 25 cavities per square centimeter to about 1,100 cavities per square centimeter resulting in increased surface area and therefore enhanced heat transfer capability. Also disclosed is a mold for forming a pattern for molding the casting. The mold includes a surface defining a portion of a chamber to which are attached a plurality of particles having an average particle size in a range of about 300 microns to about 2,000 microns.

Abstract: Apparatus for forming a pour hole and main sprue in an investment mold for lost wax casting. A sprue having a flared base, a base member adapted to receive the flared base of the sprue for vertically supporting the sprue, and a flask for containing investment material immersing the sprue, define the casting apparatus of the present invention. The present investment casting sprue apparatus forms a pour hole in the hardened investment material suitable for smoothly introducing liquid metals into the cavity formed by the sprue, thereby reducing the number of casting defects related to turbulent filling. This is accomplished as a result of the flared base of the sprue, which forms a gentle transition into the sprue. The current practice, by contrast, uses a sprue having a cylindrical base which is simply inserted into a hole in a finger or button formed in the supporting base member for the sprue without regard to this smooth transition.

Abstract: A crystal selector pattern for use in forming a mould in an investment casting process, which is formed from a water-soluble organic composition which, in a preferred embodiment, comprises 80% urea.

Abstract: Fold defects are reduced or eliminated in lost foam castings by contacting a destructible polymeric pattern surface proximate to which deleterious fold defects comprising unbonded seams are prone to form in the solidifying molten metal with a material that reduces or eliminates fold defects in the casting proximate the pattern surface. The material can comprise a silicone layer that is anti-sticking relative to a gas permeable refractory layer on the pattern or foundry sand directly contacting the pattern surface depending on casting configuration. The pattern is cleaned prior to contact with the material. Lower melt casting temperatures can be used with concomitant improvements in casting microstructure (e.g. finer dendritic arm spacing) and mechanical properties.

Abstract: The models comprise an expanded or expansible polymer or copolymer generally used for the fabrication of such models. The polymer or copolymer contains an oxidizing agent comprising a nitroaliphatic compound that accepts expansion without substantial alteration of its oxidizing properties, that does not substantially modify the characteristics of the polymer or copolymer before, during and after expansion, that does not harm the quality of the metal that is cast, and that has a decomposition temperature essentially identical to that of the polymer or copolymer.

Abstract: The pattern material with substantially spherical filler particulates is used to produce investment cast components with improved surface quality, reduced finishing costs, and reduced core breakage. The pattern material comprises substantially spherical particles within the particle size range of about 10 microns to about 70 microns particle diameter, the use of which reduces the number of random, localized surface depressions and pits to improve pattern surface texture and uniformity. Patterns so formed inpart the same improvements to the surface of subsequent investment cast components. The resulting castings exhibit improved as-cast surface finish and reduced random, localized surface pitting, thereby reducing or eliminating expensive post casting surface finishing operations. Moreover, the spherical morphology of the filler particulates reduces injection pressures to fill a pattern die cavity as compared to non-spherical filler particulates.

Abstract: A soluble wax core insert to be used in making a wax replica of a hollow metal jewelry ring has an inner round radius design and an arcuate portion having an arcuate extent of at least 140.degree.. The soluble wax core insert is formed by molding in a metal mold. Once formed, the core insert is placed in another metal mold and a plastiwax is introduced into and fills a cavity around the core insert. The plastiwax hardens and is removed from the latter mold with the core insert embedded in the hardened plastiwax article. The wax core insert is removed from the plastiwax article to yield a wax replica of the metal ring to be produced. The wax replica has an inner round radius design and is used to form a mold cavity in an investment material, which is used to cast the hollow metal jewelry ring.

Abstract: An improved method of lost foam casting of aluminum silicon alloys utilizing a pattern formed of an expandable polymeric foam having a decomposition temperature less than 300.degree. C., and a heat of decomposition less than 600 Joules per gram. The foam pattern preferably has a heat of fusion less than 60 Joules per gram and a bulk density in the range of one to four pounds per cubic foot. The lost foam casting procedure has particular use when casting hypereutectic aluminum silicon alloys containing from 16 to 30% silicon, and eliminates the "liquid styrene" defect which occurs when casting such alloys in a lost foam process utilizing conventional polystyrene foam patterns. When casting hypoeutectic aluminum-silicon alloys containing from 5% to 8% silicon, the method eliminates the "fold" defect.

Abstract: A pattern from which cast nodes can be produced, the pattern including a central ring or disc against which one or more stubs abut at selected stations to enable nodes of differing annular geometries and/or stub diameter to be produced from the same pattern.

Abstract: A nail polish or nail polish/enamel composition is applied to imperfections, errors, distortions or porosities in the model. The composition is thus used to correct the model's shape. The composition can be added at room temperature, and avoids the need to utilize high temperatures in the process of building the model. The nail polish or nail polish/enamel compositions may be utilized to add jewelry design elements to the model.

Abstract: A spruing assembly for receiving investment material in the production of an investment mold for castings by the "lost wax" process which includes a hollow chamber to receive the investment material. Included within the chamber is one or more sprue for supporting the wax pattern(s) to be cast and one or more corresponding predetermined shaped reservoir(s) being slidably moveable up or down the sprue to create the heat center of the investment mold. Where a long span casting is to be produced all the reservoirs are connected to form a continuous reservoir or Feeder Bar which conforms to the curve of a long span dental arch. A base member is provided within the chamber for supporting the sprue.

Abstract: A wax pattern for use in connection with investment casting of a metal wood golf club head, in which the golf club head is a positive duplicate of the wax pattern. The wax pattern includes a body having a hollow interior accessible through an orifice and a weld rim surrounding the orifice with gate forming means that include at least one gate disposed on the weld rim.

Abstract: Disclosed herein is a one piece drive shaft housing comprising a casting including an outer surface having an upper end surface, a lower end surface, and an endless side surface extending between the upper and lower end surfaces, an internal cavity extending between the upper and lower end surfaces and adapted to receive a drive shaft and a clutch operated linkage, an internal exhaust gas passage extending between the upper and lower end surfaces and located in spaced relation to the cavity, an internal coolant supply passage extending between the upper and lower end surfaces, an internal idle exhaust passage including a series of expansion chambers and extending between the upper end surface and the endless side surface, and an internal coolant drainage passage extending between the upper and lower end surfaces in heat exchanging relation to the exhaust gas passage.

Abstract: An improved mold for use in casting a metal airfoil has an airfoil mold cavity and a starter chamber. A lower end of the starter chamber is formed by a chill plate. A filter is disposed in the starter chamber between the airfoil mold cavity and the chill plate. When an airfoil is to be cast, molten metal is conducted into the starter chamber, into passages in the filter and into the airfoil mold cavity. The molten metal is solidified upward in the starter chamber from the chill plate and through the passages in the filter. The filter blocks migration of impurities from the starter chamber to the airfoil mold cavity as the metal solidifies in the starter chamber. As the molten metal begins to solidify in the airfoil mold cavity, the molten metal is solidified as a large number of columnar grain crystals which extend from the passages in the filter into the airfoil mold cavity.

Abstract: An assembly for making a wax pattern of a hollow component includes a pattern die and a noncircular core which is located within the pattern die. The pattern die is a split die and includes two halves which have shaped internal surfaces to define the external shape of the wax pattern of the hollow component. The core has shaped external surfaces which define the internal shape of the wax pattern of the hollow component. The core has coaxial circular cross-section projections which locate within correspondingly shaped and dimensioned apertures in the pattern die. One of the apertures in the pattern die has a radially extending pin which is arranged to mate in a groove on the projection to locate the core longitudinally. The core is allowed to rotate within the die so that chaplets on the core position the core accurately without imposing strains on the core.

Abstract: A cast tubular structure including an integral hose connection element formed thereon is produced by lost foam casting wherein a circular socket seat is formed on a pattern for a body portion of the cast tubular structure and a cylindrical pattern for the integral hose connection element is formed by a mold without vent openings on the mold surface in the area of the cylindrical pattern corresponding to the hose sealing surface of the cast tubular structure. The pattern sections are joined with the pattern section for the hose connection element sealing within the circular socket seal formed in the body portion of the cast structure.

Abstract: The pattern, composed of a polymeric material, is formed of three sections joined together by an adhesive along a pair of parallel parting lines. One parting line lies in a plane extending through the axis of an outlet to the engine block and through the axis of a sea water inlet, while the second parting line lies in a plane that extends through the axes of outlets leading to the exhaust manifolds of the V-engine. An inlet opening, through which coolant is received from the engine block, is located in one of the pattern sections and the axis of the inlet opening is normal to the parting lines.

Abstract: An evaporable foam pattern for casting the engine block of a two-cycle engine. The pattern has a crankcase end and a head end and a plurality of cylinders extend from the crankcase end toward the head end. A plurality of transfer passages are disposed longitudinally of each cylinder and one end of each transfer passage communicates with the crankcase end, while the second or discharge end of the transfer passage communicates through a transfer port with the cylinder adjacent the head end of the pattern. The pattern is composed of a crankcase section and a head section which are joined along a parting line disposed normal to the axis of the cylinder, with the parting line intersecting the transfer passages adjacent the discharge end of the passages. A portion of the cylinder in the head section located adjacent the parting line is enlarged in diameter and is connected to the cylinder by a plurality of ledges that are disposed between the transfer passages.

Abstract: The present invention relates to a pattern for castings and the castings produced from the pattern. The pattern comprises a pattern plate including a parting plane, at least one multistage draft and at least one substantial draft extending from the parting plane. A casting having a suitable draft includes corner portions formed by the parting plane.

Abstract: An evaporable foam pattern assembly for casting a centrifugal pump housing for an internal combustion engine. The assembly comprises three pattern sections having abutting surfaces joined by adhesives along a pair of parting lines. The parting lines are parallel and disposed normal to the axis of the impeller chamber of the pump.

Abstract: A full mold for casting contains a plastic foam material lost pattern. The plastic foam material is substantially sulfur-free and can advantageously be used to provide iron alloy-based full-mold cast pieces of high quality.

Abstract: An evaporable foam pattern for casting a metal water-cooled exhaust manifold for an internal combustion engine. The assembled pattern is formed of an evaporable foam polymeric material, such as polystyrene, and includes an inner exhaust conduit composed of a generally upright body portion and a generally curved elbow portion. The body portion is provided with a plurality of inlet ports connected to the exhaust passages of a bank of cylinders, while the elbow portion defines a downwardly facing outlet. The pattern also includes an outer water jacket which is spaced from the exhaust conduit to provide a water passage therebetween. Both the exhaust conduit and the outer jacket are composed of two longitudinally split halves or sections having abutting edges, and the abutting edges are joined together by an adhesive. Spacing ribs interconnect the inner surface of the jacket and the outer surface of the exhaust conduit to space the sections apart.

Abstract: An evaporable foam pattern for casting a metal air induction manifold for an internal combustion engine. The pattern is formed from an evaporable foam material, such as polystyrene, and in the assembled condition the pattern is in the form of an elongated body member having a generally rectangular cross section. One end of the body member is enclosed by an end wall while the opposite end of the body member is open. One of the side walls of the body member is provided with a plurality of generally parallel slots which are elongated in a lateral direction with respect to the longitudinal axis of the body member. The pattern is composed of a pair of longitudinal pattern sections each being generally U-shaped in cross section and having abutting edges disposed on a parting line. An adhesive joins the abutting edges. The parting line between the pattern section splits the opening in the end of the body member and all of the slots are formed in one pattern section.

Abstract: A polystyrene foam pattern (10) is provided for the cylinder block of a crankcase compression two-cycle engine having transfer passages (15) formed in the block. The pattern includes a head-end component (12) and a crankcase end component (11) mating with each other. The mating surfaces extend through the transfer ports (14), transfer passages (15), and exhaust ports (16) to allow the formation of complex passages with die cast pattern components.

Abstract: High melting point metallic, e.g., steel mold members are facilely and inexpensively produced by depositing, e.g., flame-spraying, droplets of a melt of a metal having a high melting point onto the front face surface of an elastomeric silicone mold pattern, said elastomeric silicone containing from 20 to 90% by weight of finely divided particulates of at least one refractory filler, and thereafter permitting said melt to solidify.

Abstract: A method, apparatus and feeder sleeves are described for producing casting moulds having feeder sleeves incorporated therein in instances when the mould pattern plate or the cope mould are not accessible. Two part feeder patterns having a lower part and an upper part and feeder sleeves whose lateral surface tapers from the bottom and to the top end of the sleeve are used. For moulds having a side feeder the lower part of the pattern produces a depressed seating surface for the feeder sleeve in the drag mould and the upper part which has substantially the same taper as the taper of the feeder sleeve and dimensions greater than the corresponding dimensions of the lateral surface of the feeder sleeve produces a cavity in the cope mould. The cope and drag moulds are closed in such a manner that the central vertical axis of the cavity in the cope mould is in line with the central vertical axis of the feeder sleeve, and there is a gap between the wall of the cavity and the outer lateral surface of the sleeve.

Abstract: A foam mold pattern assembly comprising a pattern having opposite first and second ends, a first projection connected to the pattern for facilitating suspension of the foam mold pattern assembly with the first end facing generally upwardly, and a second projection connected to the pattern for facilitating suspension of the foam mold pattern assembly with the second end facing generally upwardly.

Abstract: A foam mold pattern for making an engine block in a lost foam casting process, the pattern comprising an upper portion including a cylinder bore upper portion, and an upper portion of an exhaust port and an upper portion of an inlet port communicating with the cylinder bore upper portion, and a lower portion including a cylinder bore lower portion and being attached to the pattern upper portion such that the cylinder bore lower portion is aligned with the cylinder bore upper portion.

Abstract: A wax profile for making a tooth for a dental bridge, the tooth having a cast gold alloy skeleton and porcelain coating, the skeleton being cast in a negative mold made from the wax profile and having the same shape as the wax profile. The wax profile having a wax, tooth-shaped body. The body having aligned upper and lower cavities connected vertically with a median channel to provide said porcelain coating filling the spaces of the cavities and channel with increased strength responsive to compressive forces applied vertically of the tooth.

Abstract: An internal combustion V-8 engine is disclosed having an aluminum semi-permanent mold head cast by a low-pressure die-cast process and an iron block cast by the evaporative casting method. The block and head have controlled thickness walls throughout to optimally lower the metal/working volume ratio of the engine. The block employs barrel cylinder walls cast integrally and unsupported except at the barrel ends and at a siamese connection between adjacent barrels; the barrels are maintained under a predetermined level of compression to eliminate fatigue failure and suppress sound. The block is sand cast and the head is totally formed with a three piece die and one sand core cluster, except for one passage which is drilled subsequent to casting. The engine is reduced in weight by at least 20% over conventional comparable engines; torque and horsepower is improved even though the cooling system capacity has been reduced to less than half that of a conventional cooling system.

Abstract: An improved mold for casting single crystal metallic articles is disclosed and comprises a ceramic investment mold having a main article cavity and having embedded at its lower end below the article cavity and in communication therewith a preformed ceramic single crystal starter insert. The preformed starter insert generates a plurality of single metallic crystals in a growth cavity and then selects one crystal for further propagation through the article cavity. A method for making such a mold is also disclosed.

Abstract: The present invention provides means for the improved positioning of a strongback in a pattern mold for formation of expendable patterns thereon. Investment casting molds formed around the assembly of strongback and patterns are characterized as having the strongback precisely and reproducibly suspended therein. Articles, such as turbine blade halves, cast in such investment molds have mating surfaces in close dimensional relationship and can be bonded one to any mating other to form a finished product.In particular, a strongback having bonding locators near the opposite ends thereof is provided with additional locators to be used in suspending the strongback in the pattern mold. According to the invention, these pattern mold locators are colinear with and in close proximity to the bonding locators and are engaged by locating means in the pattern mold for establishing precise positioning of the strongback therein.

Abstract: The present invention provides a method for improved positioning of a strongback in a pattern mold for formation of expendable patterns thereon. Investment casting molds formed around the assembly of strongback and patterns are characterized as having the strongback precisely and reproducibly suspended therein. Articles, such as turbine blade halves, cast in such investment molds have mating surfaces in close dimensional relationship and can be bonded one to any mating other to form a finished product.In particular, improved positioning of the strongback in the pattern mold is achieved by suspending the strongback from the bonding locators by expendable locating means; that is, locating means which are incorporated into the patterns formed on the strongback surfaces. The use of expendable locating means enables the bonding locators to also serve as locators for positioning the strongback in the pattern mold and essentially eliminates errors in strongback positioning due to tolerances associated therewith.

Abstract: This invention involves a method of making a unitary pattern assembly which is useful in forming investment shell molds for the conventional and directional solidification of molten metals and alloys. It comprises providing a fixture having first and second pattern capturing means, providing a mold structure having a cavity, positioning the mold structure and fixture to expose the capturing means to the cavity, forming a pattern in the cavity and removing the mold structure from the pattern. A unitary pattern assembly comprising a fixture and pattern fixedly captured therein is obtained. Multiple patterns may also be captured in the fixture. The method is especially suitable for making a pattern assembly useful in the production of gas turbine engine blades by the "lost wax" process.

Abstract: A flash control molding is provided for use in association with a pattern for forming a casting cavity in a metal casting mold. The flash control molding includes an elongated strip of pliable material having a predetermined cross sectional configuration to define a thick portion for forming a flash control chamber in the mold, and a thin edge along one side of the thick portion to form a restricted opening between the flash control chamber and the casting cavity so that a casting subsequently produced in the mold is formed with controlled shaped flash which has a built-in fracture line immediately adjacent the casting proper, thereby making the flash easily and cleanly removable from the casting.

Abstract: A method of making a more economical and reliable treating agent for use in late metal treatment when pouring metal castings. The treating agent is defined as an essentially homogeneous solid cast block preferably containing alloying ingredients to nodulize or inoculant ferrous metal. Each block is designed to present a generally uniform reaction surface to molten metal to be treated. This is obtained by casting the block to a shape which snugly fits a prepared basin in the mold gating system over which the molten metal to be treated must flow, or to cast the block in an annular configuration through which the molten metal must flow. The latter block has contoured inner surfaces which maintain a generally constant reactive surface as the block is consumed. These blocks are preferably prepared by simultaneously casting a large number in closely nested relation.