Means Providing Inert Or Reducing Atmosphere Patents (Class 164/259)
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Patent number: 11148194Abstract: A casting system and process employs sealed lightweight mold segments that are assembled into a fixture that serves as a mold transportation device that is delivered via a mold line to a production line roll-over system which performs as a metal pouring station. This system may be employed in sand, semi-permanent and permanent casting environments. The fixture is pressurized with He, inverted by the roll-over system, then connected to a low-pressure furnace where metal pouring begins while maintaining pressurized He in the mold cavity. A counter-gravity delivery system allows the low-pressure furnace to deliver molten lightweight material that is free from oxides and dissolved hydrogen gas into the mold cavity.Type: GrantFiled: May 10, 2018Date of Patent: October 19, 2021Inventor: Adolf Hetke
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Patent number: 10702915Abstract: An injection device of a light metal injection molding machine includes: a first inert gas storage part creating an inert gas atmosphere around a plunger insertion portion of an injection cylinder; a second inert gas storage part housing surplus molten metal in a melting cylinder and creating an inert gas atmosphere above the molten metal; and a first pressure adjustment part adjusting a pressure in the first inert gas storage part to a pressure equal to or less than a pressure obtained by adding a pressure, which is determined based on a value obtained by multiplying a specific gravity of the molten metal by a height difference between a highest position and a lowest position of the molten metal in a part that includes the inside of the injection cylinder and communicates with the inside of the injection cylinder, and a pressure in the second inert gas storage part.Type: GrantFiled: June 5, 2019Date of Patent: July 7, 2020Assignee: SODICK CO., LTD.Inventor: Misao Fujikawa
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Patent number: 10478890Abstract: Methods of billet casting are provided herein. The methods may include the steps of assembling a billet caster with a shroud extending from a tundish to above a mold such that the shroud does not reach molten metal in the mold, delivering molten metal from a ladle into the tundish, delivering molten metal from the tundish through the shroud to the mold, the shroud inhibiting contact between the molten metal and air, casting the molten metal into billets in the mold and cooling the billets below the mold with a coolant spray, and delivering the cooled billet to a runout table to be cut to length.Type: GrantFiled: June 20, 2017Date of Patent: November 19, 2019Assignee: Nucor CorporationInventors: David J. Sosinsky, Marcie M. Hinker
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Patent number: 9587313Abstract: A substrate processing apparatus includes: a reaction tube configured to accommodate a plurality of substrates and to be supplied with a gas generated by vaporizing or turning into mist a solution containing a reactant in a solvent; a lid configured to close the reaction tube; a first heater configured to heat the plurality of substrates; a thermal conductor placed on the lid on an upper surface thereof; a second heater placed outside the reaction tube around a side thereof, the second heater being configured to heat the gas flowing near the lid; and a heating element placed on the lid on a lower surface thereof, the heating element configured to heat the lid.Type: GrantFiled: January 26, 2015Date of Patent: March 7, 2017Assignee: HITACHI KOKUSAI ELECTRIC INC.Inventors: Yuichi Wada, Hiroshi Ashihara, Hideto Tateno, Harunobu Sakuma
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Patent number: 9186722Abstract: Provided is a tilt type gravity molding device which requires no riser, prevents increase in length of a sprue runner, suppresses occurrence of clogging of a molten metal, and facilitates temperature control of the molten metal. The tilt type gravity molding device includes: a mold having defined therein a product forming space for forming a molded product, and configured to receive a molten metal from a pouring gate; a ladle including: a storing section capable of storing the molten metal therein; and a plate-like opening/closing body abutting on the mold, and having an injection port capable of being aligned with the pouring gate; and a gas supplying section for supply gas into the product forming space. The ladle is slidably mounted to the mold, and is slidable between an opening state in which the injection port is aligned with the pouring gate, and a closing state in which the plate-like opening/closing body closes the pouring gate.Type: GrantFiled: February 25, 2014Date of Patent: November 17, 2015Assignee: MORIKAWA KANAGATA CO., LTD.Inventors: Shunichi Morikawa, Tadayuki Yano
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Patent number: 9022096Abstract: A casting apparatus having a main chamber connected to at least one casting tower. The main chamber may contain molten metal and the temperature within the main chamber may be maintained by a furnace. A pump may pump the molten metal up the tower and into an upper pool chamber. A feeder nozzle may feed the molten metal from the upper pool chamber and onto a chilling wheel, which may turn the molten metal into metal flakes.Type: GrantFiled: November 25, 2013Date of Patent: May 5, 2015Inventors: Larry Joe Eshelman, Edna Marie Eshelman
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Publication number: 20150000857Abstract: A vacuum container includes a connecting chamber a valve chamber, a discharging chamber, and a sealing member. The connecting chamber defines an inclined sealing surface. The discharging chamber defines a discharging passage therein. The valve chamber interconnects the connecting chamber and the discharging chamber. The sealing member is slidably received in the valve chamber, wherein the sealing member is configured for sliding toward the sealing surface, such that the sealing member resists the inclined sealing surface to hermetically isolate the connecting chamber from the discharging chamber.Type: ApplicationFiled: June 30, 2014Publication date: January 1, 2015Inventors: TANG-QUAN CHEN, XIAN-HE LI, YI-MIN JIANG
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Publication number: 20140352907Abstract: A die casting apparatus (100) for amorphous alloy comprises a stationary die (1) and a movable die (2); a sealed cabin (4) difining a sealing chamber (40); a protecting gas supplying device connected with the sealed cabin (4) for supplying the protecting gas into the sealing chamber (40); a melting device (5) for receiving and melting amorphous alloy; a feed sleeve (6) having a molten material inlet (60), with a plunger (7) positioned therein for injecting the molted amorphous alloy from the melting device (5) into a die chamber via the molten material inlet (60); a driving device (8) connected with the plunger (7) for driving the plunger (7) in the feed sleeve (6); and a gas purifying device (10) communicated with the sealed cabin (4) for purifying the gas from the sealed cabin (4).Type: ApplicationFiled: December 13, 2012Publication date: December 4, 2014Inventor: Faliang Zhang
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Publication number: 20140262113Abstract: A process and tools for forming spherical metal balls is described incorporating molds, injection molded solder, a liquid or gaseous environment to reduce or remove metal oxides and an unconstrained reflow of metal in a heated liquid or gas and solidification of molten metal in a cooler liquid or gas.Type: ApplicationFiled: March 18, 2013Publication date: September 18, 2014Applicant: INTERNATIONAL BUSINESS MACHINES CORPORATIONInventor: INTERNATIONAL BUSINESS MACHINES CORPORATION
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Publication number: 20140182806Abstract: A system (1) for injecting semisolid metal (3) into a mould (2), comprises —a mould (2) which comprises a mould chamber (16) suitable to receive the metal through a mould injection mouth (17); —at least one press device (4) for pressure-injecting metal (3) in said mould (2); —said at least one press device comprises a cylinder (5) having a substantially vertical axis (X-X) and a mouth (15) for coupling to the injection mouth (17) of said mould (2) and a thrust piston (6) accommodated within said cylinder, defining with said cylinder an injection chamber (7) suitable to contain molten metal (10); —said cylinder (5) having passageways (8) to receive cooling fluid (9) for cooling said molten metal (10) poured into said injection chamber (7) in semisolid metal (3); —a cup (18) for drawing the molten metal (10) and pouring the latter into said injection chamber (7); —a positioning device (11); —said positioning device (11) supporting a blending device (12), said blending device (12) having an active portion (14) aType: ApplicationFiled: May 15, 2012Publication date: July 3, 2014Applicant: FRENI BREMBO S.p.A.Inventors: Renzo Moschini, Marcello Boschini, Cristian Crippa
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Publication number: 20140182804Abstract: The embodiments described herein relate to methods and apparatus for counter-gravity formation of BMG-containing hollow parts. In one embodiment, the BMG-containing hollow parts may be formed by first feeding a molten metal alloy in a counter-gravity direction into a mold cavity to deposit the molten metal alloy on a surface of the mold cavity and then solidifying the deposited molten metal alloy.Type: ApplicationFiled: March 6, 2014Publication date: July 3, 2014Applicants: Crucible Intellectual Property, LLC, Apple Inc.Inventors: Theodore A. Waniuk, Joseph Stevick, Sean O'Keeffe, Dermot Stratton, Joseph Poole, Matthew Scott, Christopher Prest
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Publication number: 20140166230Abstract: A casting apparatus having a main chamber connected to at least one casting tower. The main chamber may contain molten metal and the temperature within the main chamber may be maintained by a furnace. A pump may pump the molten metal up the tower and into an upper pool chamber. A feeder nozzle may feed the molten metal from the upper pool chamber and onto a cooling wheel, which may turn the molten metal into metal flakes.Type: ApplicationFiled: November 25, 2013Publication date: June 19, 2014Inventors: Larry Joe Eshelman, Edna Marie Eshelman
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Publication number: 20130306198Abstract: Described herein is a method of selectively depositing molten bulk metallic glass (BMG). In one embodiment, a continuous stream or discrete droplets of molten BMG is deposited to selected positions. The deposition can be repeated as needed layer by layer. One or more layers of non-BMG can be used as needed.Type: ApplicationFiled: May 16, 2012Publication date: November 21, 2013Applicants: Crucible Intellectual Property LLC, Apple Inc.Inventors: Christopher D. Prest, Joseph C. Poole, Joseph Stevick, Theodore Andrew Waniuk
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Publication number: 20130156637Abstract: A method for making an equiaxed investment casting. The method utilizes an ultrasonic generator to send an ultrasonic pulse into molten metal in an investment casting mold. The investment casting mold is positioned within a working zone of furnace having low output induction coils for generating a convection current in molten metal. The ultrasonic pulse separates dendrites growing from the face of the mold inward into the molten metal. Instead, equiaxed grains can nucleate within the molten metal. In addition, the ultrasonic pulse and the low output induction coils circulate the molten metal as solute is rejected from solidifying equiaxed grains. The mixing reduces the effects of segregation in the solidifying alloy and assists in nucleating equiaxed grains.Type: ApplicationFiled: December 20, 2011Publication date: June 20, 2013Applicant: GENERAL ELECTRIC COMPANYInventors: Junyoung PARK, Jason Robert PAROLINI, Ibrahim UCOK
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Publication number: 20120328470Abstract: Apparatus is provided for forming aluminum alloy ingots in a sealed chamber having a source of inert gas using a crucible positioned inside the chamber for melting aluminum alloy powder. The crucible has a solid top and a source of inert gas therein. An outlet in the crucible is positioned to draw molten alloy from the crucible at a point proximate the lowest point in the crucible.Type: ApplicationFiled: June 27, 2011Publication date: December 27, 2012Applicant: UNITED TECHNOLOGIES CORPORATIONInventor: Thomas J. Watson
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Publication number: 20120298322Abstract: A casting apparatus and a method of forming a casting using the casting apparatus is disclosed, the casting apparatus comprising a ladle having a hollow interior adapted to receive a molten material therein; a nozzle in fluid communication with the hollow interior, the nozzle having a first portion disposed outside of the ladle and a second portion disposed within the hollow interio; an additive feeder in fluid communication with the hollow interior of the ladle; and a gas conduit in fluid communication with the hollow interior of the ladle.Type: ApplicationFiled: May 25, 2011Publication date: November 29, 2012Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLCInventors: Christopher D. Cogan, Stephen M. Fitch, Qigui Wang
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Patent number: 8302657Abstract: A casting process for an aluminum alloy containing at least about 0.1% of Mg and/or at least about 0.1% of Li in which a liquid surface of the alloy is put into contact with a dried gas including at least about 2% of oxygen by volume and with a water partial pressure lower than about 150 Pa throughout most of the solidification process is described. The process makes it possible to cast most oxidable aluminum alloys, in particular aluminum alloys containing magnesium and/or lithium, without using additives such as beryllium and/or calcium and without using expensive devices and/or gases, to obtain cast ingots generally free from surface defects and pollution, in complete safety.Type: GrantFiled: February 16, 2010Date of Patent: November 6, 2012Assignee: Constellium FranceInventors: Guillaume Bes, Robert Rey-Flandrin, Olivier Ribaud, Stephane Vernede
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Patent number: 8230897Abstract: A low-pressure casting apparatus that prevents molten metal that is a residue in a conduit from being oxidized. The low-pressure casting apparatus includes a compartment for holding a molten metal 1, a pressure chamber 2 that can communicate with the compartment, wherein the molten meal is pressurized in the chamber, an on-off valve 5 that opens and closes hole 4 through which the compartment can communicate with the pressure chamber, a conduit 7 that conducts the molten metal to the mold 6, wherein the base of the conduit is connected to a lower part of the chamber so as to communicate with the chamber, the end of the conduit being made so that it can communicate with a sprue for a mold 6, a float 9 that goes up and down in the pressure chamber, and a tank that stores an inert gas and that has a pipe 13 that is connected to the upper part of the pressure chamber 2.Type: GrantFiled: April 1, 2008Date of Patent: July 31, 2012Assignee: Sinokogio, Ltd.Inventors: Takahiro Tamura, Yutaka Murata
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Patent number: 8191608Abstract: A device for low-pressure casting wherein the stalk or the guiding tube is filled with inert gas by causing the space formed over the molten metal in the pressurizing room to communicate with the stalk or the guiding tube.Type: GrantFiled: April 8, 2008Date of Patent: June 5, 2012Assignee: Sintokogio, Ltd.Inventors: Shinya Mizuno, Yutaka Murata
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Publication number: 20110232855Abstract: A digital manufacturing system comprises a build chamber, a build platform disposed within the build chamber, at least one extrusion line configured to heat a metal-based alloy up to a temperature between solidus and liquidus temperatures of the metal-based alloy, a deposition head disposed within the build chamber and configured to deposit the heated metal-based alloy onto the build platform in a predetermined pattern, an umbilical having a first end located outside of the build chamber and a second end connected to the deposition head, and at least one gantry assembly configured to cause relative motion between the build platform and the deposition head within the build chamber, where the at least one gantry assembly comprises a motor disposed outside of the build chamber.Type: ApplicationFiled: April 8, 2011Publication date: September 29, 2011Applicant: STRATASYS, INC.Inventors: S. Scott Crump, J. Samuel Batchelder, Timothy Sampson, Robert L. Zinniel, John Barnett
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Patent number: 7984747Abstract: A control method for supplying an inert gas from an inert gas source to a storage container for a molten metal through a gas feed path provided with a flow sensor for monitoring the gas flow rate and a solenoid valve for opening and closing the gas feed path for use with metal molding. The control method includes steps of turning off the solenoid valve if a temperature of the storage container is lower than a preset temperature, and turning off the flow sensor; otherwise turning on the solenoid valve and turning on the flow sensor; and stopping the output of the heater of the storage container when the gas flow rate is lower than the preset amount; these steps are controlled in accordance with a command signal from a controller.Type: GrantFiled: January 21, 2009Date of Patent: July 26, 2011Assignee: Nissei Plastic Industrial Co., Ltd.Inventors: Yasuhiko Takeuchi, Mamoru Miyagawa, Ikuo Uwadaira
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Patent number: 7896059Abstract: Disclosed is a metal casting system, an engineered mold for use therewith, a process for utilizing the system and mold, and articles having a clean, oxide-free sand casting of molten metals that have been produced under an inert environment. This is especially advantageous for making automotive and airplane parts from the manufacture of lightweight metals, and more especially for the production of magnesium parts in order to reduce weight while maintaining properties found in other lightweight metals. Currently, sand cast articles are being used for automotive, aerospace and semiconductor parts and other industrial applications.Type: GrantFiled: January 3, 2007Date of Patent: March 1, 2011Inventor: Adolf Hetke
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Publication number: 20100212855Abstract: The invention relates to a casting process for an aluminum alloy containing at least about 0.1% of Mg and/or at least about 0.1% of Li in which a liquid surface of said alloy is put into contact with a dried gas including at least about 2% of oxygen by volume and with a water partial pressure lower than about 150 Pa throughout most of the solidification process. The invention makes it possible to cast the most oxidable aluminum alloys, in particular aluminum alloys containing magnesium and/or lithium, without using additives such as beryllium and/or calcium and without using expensive devices and/or gases, to obtain cast ingots free from surface defects and pollution, in complete safety.Type: ApplicationFiled: February 16, 2010Publication date: August 26, 2010Applicants: ALCAN RHENALU, ALCAN ALUMINIUM VALAISInventors: Guillaume Bes, Robert Rey-Flandrin, Olivier Ribaud, Stephane Vernede
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Publication number: 20100044003Abstract: A method and apparatus involve positioning an insert within a cavity of a mold, heating an insert wall within the cavity of the mold, and casting a molten metal into the cavity adjacent the insert. A surface of the insert absorbs heat from the molten metal to melt and fuse to the molten metal.Type: ApplicationFiled: August 24, 2009Publication date: February 25, 2010Inventor: Mark A. Baumgarten
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Publication number: 20090139682Abstract: A nucleated casting apparatus including an atomizing nozzle configured to produce a droplet spray of a metallic material, a mold configured to receive the droplet spray and form a preform therein, and a gas injector which can limit, and possibly prevent, overspray from accumulating on the mold. The gas injector can be configured to produce a gas flow which can impinge on the droplet spray to redirect at least a portion of the droplet spray away from a side wall of the mold. In various embodiments, the droplet spray may be directed by the atomizing nozzle in a generally downward direction and the gas flow may be directed in a generally upward direction such that the gas flow circumscribes the perimeter of the mold.Type: ApplicationFiled: December 4, 2007Publication date: June 4, 2009Applicant: ATI Properties, Inc.Inventors: Robin M. Forbes Jones, Sterry A. Shaffer
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Publication number: 20080164000Abstract: The invention relates to a casting method for aluminium or aluminium alloys, in which molten aluminium is treated and fed to at least one casting station (33, 34), in which the molten metal is cast into semi-finished products or similar. A number of casting ladles (25) are used to treat and feed the molten aluminium to the respective casting station (33, 34). The ladles are filled with the molten metal and the latter is then transported to at least one additional stage (32), where it is treated. The molten metal is subsequently delivered in the ladles (25) to the casting station (33, 34), where the ladles (25) are emptied. The invention thus provides an efficient method that can be flexibly adapted to the time periods of the process, said periods altering according to the situation.Type: ApplicationFiled: June 16, 2005Publication date: July 10, 2008Applicant: STOPINC AKTIENGESELLSCHAFTInventors: Dirk Kotze, Dawid Dewet-Smith
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Publication number: 20080115906Abstract: A method and apparatus for preparing and delivering various types of carbon and microalloy steel, free of oxygen with abundance of nuclei, when cast producing ultra fine grain steel free of internal defeats with excellent quality. A horizontal sealed table caster has a chamber, containing a suitable atmosphere for casting, with a tube connecting to a tundish so as to allow a liquid to flow into the chamber. The liquid metal is captured on a cooling belt along the bottom of the chamber and is maintained as a specific width and depth. The cooling belt serves as a heat sink causing the liquid metal to solidify from the bottom up, allowing inclusions to migrate to the surface of the steel. A layer of liquid metal is maintained on top of the solidifying steel until the solidification reaches the surface. The belt moves the solid metal toward the exit of the chamber.Type: ApplicationFiled: November 22, 2006Publication date: May 22, 2008Inventor: Oren V. Peterson
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Patent number: 7290588Abstract: A protective gas device for the melting furnaces of pressure die-casting machines, in particular for processing a magnesium melt. A collection container of a mixing device for the components of a protective gas, which covers the melt to prevent oxidation or other damage, is configured as a pressure accumulator and the orifices for feeding the protective gas into the melting furnace are provided with inlet nozzles. Gas flow to the inlet nozzles is regulated by metering devices. The operating pressure is equal to or less than the pressure in the pressure accumulator of the mixing device, but high enough to atomise the jets and produce a turbulent inflow behind the inlet nozzles. Said pressurized protective-gas distribution permits the metering of gas into various furnace chambers or furnaces without repercussions. A uniform concentration of the protective gas can be achieved in all areas by the selective arrangement of the inlet nozzles.Type: GrantFiled: September 19, 2003Date of Patent: November 6, 2007Assignee: Oskar Frech GmbH & Co. KGInventors: Norbert Erhard, Ulrich Schraegle, Gerd Mentel
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Patent number: 7210516Abstract: A casting apparatus including a die that contains a molten metal that is poured via an opening section disposed above the die. The casting apparatus also includes a heater disposed above the die, and a gas supplying structure for supplying an inter gas to a surface of the molten metal. The casting apparatus further includes a lid disposed between the surface of the molten metal and the heater, and a lid moving structure for moving the lid to the die relatively so as to control the opening amount of the opening section above the die.Type: GrantFiled: July 24, 2003Date of Patent: May 1, 2007Assignees: Mitsubishi Materials Corporation, Japan Electric Metals Corporation, LimitedInventors: Saburou Wakita, Junichi Sasaki, Yuuji Ishiwari, Kouji Tsuzukihashi
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Patent number: 6923242Abstract: An aluminum casting method includes the step of applying in advance a mold release agent including magnesium to a mold surface. Thereafter, a nitrogen gas is injected into a cavity to cause reaction between the magnesium in the surface of the mold release agent and the nitrogen gas, thereby forming magnesium nitride. Since the nitrogen gas reacts only with the magnesium exposed in the surface of the mold release agent, the forming time of the magnesium nitride is reduced and also the amount of nitrogen gas used is reduced.Type: GrantFiled: June 27, 2002Date of Patent: August 2, 2005Assignee: Honda Giken Kogyo Kabushiki KaishaInventors: Yasuhiro Nakao, Hiroto Shoji, Kunitoshi Sugaya, Takashi Kato, Takaharu Echigo, Satoshi Matsuura, Kenichi Kawasaki
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Patent number: 6752197Abstract: An injector particularly for a vacuum die-casting apparatus, comprising an injector body provided with at least one first opening for injecting/aspirating a protective gas and at least one second opening for loading molten material, which are arranged in order of operation. The injector body is further provided with a chamber for containing material and for the sliding of a piston for pushing the material into a die. The injector also comprises elements for cleaning and lubricating the external surface of the piston which are arranged in order of operation on a corresponding supporting element which is separate from the injector body.Type: GrantFiled: June 12, 2001Date of Patent: June 22, 2004Assignee: Idra Presse S.p.A.Inventor: Graziano Mortari
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Publication number: 20040050522Abstract: A casting apparatus comprises a die 2 which contains a molten metal which is poured via an opening section which is disposed above the die, a heater which is disposed above the die, a gas supplying structure for supplying an inert gas to a surface of the molten metal, a lid 6 which is disposed between the surface of the molten metal and the heater, and a lid moving structure for moving the lid to the die relatively so as to control the opening amount of the opening section above the die.Type: ApplicationFiled: July 24, 2003Publication date: March 18, 2004Applicants: MITSUBISHI MATERIALS CORPORATION, Japan Electric Metals Corporation, LimitedInventors: Saburou Wakita, Junichi Sasaki, Yuuji Ishiwari, Kouji Tsuzukihashi
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Patent number: 6540008Abstract: Disclosed is a molten metal injector system including a holder furnace, a casting mold supported above the holder furnace, and a molten metal injector supported from a bottom side of the mold. The holder furnace contains a supply of molten metal having a metal oxide film surface. The bottom side of the mold faces the holder furnace. The mold defines a mold cavity for receiving the molten metal from the holder furnace. The injector projects into the holder furnace and is in fluid communication with the mold cavity. The injector includes a piston positioned within a piston cavity defined by a cylinder for pumping the molten metal upward from the holder furnace and injecting the molten metal into the mold cavity under pressure. The piston and cylinder are at least partially submerged in the molten metal when the holder furnace contains the molten metal. The cylinder further includes a molten metal intake for receiving the molten metal into the piston cavity.Type: GrantFiled: July 3, 2000Date of Patent: April 1, 2003Assignee: Alcoa Inc.Inventors: Thomas N. Meyer, Michael J. Kinosz, Nicolas Bigler, Guy Arnaud
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Patent number: 6536508Abstract: A molten metal supply system (90) includes a plurality of injectors (100) each having an injector housing (102) and a reciprocating piston (104). A molten metal supply source (132) is in fluid communication with the housing (102) of each of the injectors (100). The piston (104) is movable through a return stroke allowing molten metal (134) to be received into the housing (102) from the molten metal supply source (132), and a displacement stroke for displacing the molten metal (134) from the housing (102). A pressurized gas supply source (144) is in fluid communication with the housing (102) of each of the injectors (100) through respective gas control valves (146). The gas supply source (144) is used to pressurize a space formed between the molten metal (134) and the piston (104) during the return stroke of the piston (104) of each of the injectors (100).Type: GrantFiled: December 11, 2001Date of Patent: March 25, 2003Assignee: Alcoa Inc.Inventors: Vivek M. Sample, Scott E. Reighard, Vincent A. Paola, Ronald G. Chabal
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Publication number: 20030041993Abstract: The present invention provides a die-casting method comprising the steps of evacuating a cavity 30 defined by dies of a die-casting machine to provide therein a vacuum of 100 millibar or less during a first period, injecting a reactive gas from a sleeve of the die-casting machine into the cavity 30 during a second period which has a partial overlap period with the first period and follows the overlap period, so as to increase the inner pressure of the cavity to atmospheric pressure or more, pouring a molten aluminum alloy M into the sleeve 40 while keeping the injection of the reactive gas, and subsequently moving a plunger 42 in the sleeve forward to forcibly inject the molten aluminum alloy from the sleeve into the cavity 30 while re-evacuating the cavity 30. The evacuation, reactive-gas injection and re-evacuation operations can be performed with respective overlap periods therebetween.Type: ApplicationFiled: July 10, 2002Publication date: March 6, 2003Inventors: Yukio Kuramasu, Osamu Yoshida, Yoshihiro Tajima, Takaaki Ikari
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Patent number: 6505674Abstract: An injector (100) for a molten metal supply system includes an injector housing (102) configured to contain molten metal. A molten metal supply source (132) is in fluid communication with the housing (102). A piston (104) extends into the housing (102). The piston (102) is movable through a return stroke allowing molten metal (134) to be received into the housing (102) from the molten metal supply source (132), and a displacement stroke for displacing the molten metal (134) from the housing (102). A gas supply source (144) is in fluid communication with the housing (102) through a gas control valve (146). The gas supply source (144) is used to pressurize a space (148) formed between the molten metal (134) and the piston (104) during the return stroke of the piston (104) such that when the piston (104) moves through the displacement stroke a compressed gas filled space is formed.Type: GrantFiled: September 21, 2001Date of Patent: January 14, 2003Assignee: Alcoa Inc.Inventors: Vivek M. Sample, Scott E. Reighard, Vincent A. Paola, Ronald G. Chabal
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Patent number: 6488074Abstract: The present invention proposes an apparatus for casting dental prosthesis designed to save labor and costly malformations. In a form of the invention, a first arm mechanism 20 for conveying a ring and a second arm mechanism 30 for conveying a crucible are provided to slide along the same guide 27. A ring-placing platform C and a burning unit G are placed across the guide 27, and so are a crucible-placing platform D and a casting unit H. When the arm mechanism 20 places a ring on a lifting stage 44, the lifting stage 44 moves upward to contain the ring in a furnace 41, where the ring is heated to bum off the wax inside. Meanwhile, the arm mechanism 30 places the crucible in a container 50, where alloy ingots are melted. After completing the melting of the alloy ingots and the burning of the ring, the arm mechanism 20 conveys the ring onto the top of the crucible in the container 50.Type: GrantFiled: August 8, 2001Date of Patent: December 3, 2002Assignee: Denken Co., Ltd.Inventor: Masaki Usui
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Patent number: 6283196Abstract: When pouring casting cavities in casting moulds having after-feeding reservoirs, tubular lances are introduced, firstly with their point at a short distance from the after-feeding reservoir, after which the lances are pressurized from a pressure chamber and by means of a member with an inclined surface pressed downwardly through the last short distance to the after-feeding reservoir so as to pressurize the latter. With this arrangement it is possible to pressurize the after-feeding reservoirs without the need of equipping the casting moulds with complicated extra equipment and without risk of the molten metal being pressurized unnecessarily.Type: GrantFiled: September 13, 1999Date of Patent: September 4, 2001Assignee: Georg Fischer Disa A/SInventors: Ole Anders Jacobsen, Peter Møller Iversen, Uffe Andersen
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Patent number: 6253828Abstract: For the production of precision cast objects a gas change method is used. A melting crucible (1) and a casting mold (2) with at least partially porous walls are disposed in a gastight receptacle (5). The casting mold (2) with the mold cavity (3) is evacuated before the pouring-in process and subsequently flushed with a light gas, for example helium. After the mold cavity (3) is filled, the surface level (18) of the melt in the casting mold (2) is acted upon by a second heavy gas, for example argon, and subjected to excess pressure. A better degree of filling of the mold cavity (3) and an improved structure of the cast object results.Type: GrantFiled: September 22, 1999Date of Patent: July 3, 2001Inventor: Christian Reiter
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Patent number: 6192969Abstract: A method and apparatus are provided for making high purity and preferably oxygen free substantially void free and inclusion free copper castings such as billets from high purity copper. The castings are particularly useful to make sputtering targets used in sputtering deposition processes in the fabrication of electronic components. The method comprises melting high purity copper in a covered crucible using a non-contaminating heating source such as a coil induction furnace. The melted copper in the crucible is solidified using a specially controlled cooling procedure wherein the bottom of the crucible is cooled so that molten copper is maintained on top of solidified and solidifying copper until the copper is solidified.Type: GrantFiled: March 22, 1999Date of Patent: February 27, 2001Assignee: ASARCO IncorporatedInventors: Bradley D. Bunn, Jeffrey Burton, Margaret W. Staub
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Patent number: 5960853Abstract: An apparatus for the accurate formation of a three-dimensional article comprises providing a first quantity and a second quantity of substantially uniform size droplets of a desired material wherein each droplet has a positive or negative charge. Each quantity of droplets is focused or aligned into a narrow stream by passing the droplets through or adjacent an alignment means which repels each droplet toward an axis extending through the alignment means. The droplets are deposited in a predetermined pattern at a predetermined rate onto a target to form the three-dimensional article without a mold of the shape of the three-dimensional article. The droplets of the first quantity and the second quantity are supplied at different distances, whereby the droplets of the first quantity bond to each other and the droplets of the second quantity do not bond to each other or to the first quantity of droplets.Type: GrantFiled: November 5, 1997Date of Patent: October 5, 1999Assignee: Aeroquip CorporationInventors: Robert A. Sterett, Atul M. Sudhalkar, John P. Marano, Jr.
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Patent number: 5875832Abstract: The apparatus includes a cylinder for holding molten material and a plurality of molds each having a plurality of cavities for receiving molten material. As the cylinder is rotated by a driving mechanism, the molten material is passed through a plurality of holes in a cylindrical wall which surrounds the holding area where the molten material is located, and into the cavities in the molds, which are transported in series beneath the cylinder as the cylinder rotates.Type: GrantFiled: February 21, 1996Date of Patent: March 2, 1999Assignee: Dale L. HabernyInventors: Steven H. Senser, Dale L. Haberny
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Patent number: 5787965Abstract: An apparatus for the accurate formation of a free-form three-dimensional article comprises providing a supply of substantially uniform size metal droplets of a desired material wherein each droplet has a positive or negative charge in an enclosed environment. The supply of droplets is focused or aligned into a narrow stream by passing the droplets through or adjacent an alignment mechanism which repels each droplet toward an axis extending through the alignment mechanism. The droplets are deposited in a predetermined pattern at a predetermined rate onto a target to form the three-dimensional article without the use of a mold of the shape of the three-dimensional article.Type: GrantFiled: September 8, 1995Date of Patent: August 4, 1998Assignee: Aeroquip CorporationInventors: Robert A. Sterett, Atul M. Sudhalkar
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Patent number: 5685360Abstract: The casting apparatus has a case defining a casting chamber having an open front provided with a door, and a crucible locatable in the chamber for containing metal loads to be cast. An electrode extends through a wall of the chamber and is connectable to a power source for the formation of an electric arc between the electrode and the load in the crucible. A coupling connects the inside of the chamber to a source of pressurized inert gas or to a vacuum pump. A tubular element for containing a mold is removably accommodatable in the chamber at an opening, which is connected to the atmosphere by a vent valve. A fluid-activated jack is provided for tilting the case for pouring molten metal, from the crucible to the mold contained in the tubular element.Type: GrantFiled: March 14, 1996Date of Patent: November 11, 1997Assignee: Peacock Limited L.C.Inventor: Nickolas Bizzio
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Patent number: 5613545Abstract: This invention relates to an inert gas injecting plate brick or nozzle brick for use in a sliding gate valve apparatus of molten metal, characterised in that said plate brick or insert nozzle brick is horizontally split into at least two parts, and a number of small diameter pipes are sealingly arranged and secured in said split surfaces. According to such a plate brick or nozzle brick, it is possible to prevent leakage of injection gas in such kind of apparatus, it is possible to carry out a stable casting working, and complicated, high cost, additional processes such as cutting working, boring working and connecting working of said bricks can be saved.Type: GrantFiled: October 26, 1994Date of Patent: March 25, 1997Assignee: Shinagawa Refractories Co. Ltd.Inventors: Takashi Otsuka, Kenji Yamamoto, Mototsugu Osada, Tadao Taniguchi, Yoshifumi Shigeta
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Patent number: 5404929Abstract: A process for casting high oxygen affinity metals or metal alloys such as titanium through use of an induction furnace while preventing the pick up of contaminating gas by the metals or metal alloys during melting. An inert shielding gas such as nitrogen or argon or carbon dioxide is introduced as a liquid in a closed environment above the metal or metal alloys being melted such that there is preferably no more than approximately 1% contaminating gas in the gaseous environment proximate the surface of the molten metal or metal alloy. Simultaneously, the mold placed under the induction furnace is purged with a similar or different inert gas.Type: GrantFiled: May 18, 1993Date of Patent: April 11, 1995Assignee: Liquid Air CorporationInventor: Kenneth A. Till
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Patent number: 5398750Abstract: The machine includes a train of molds moving through an arcuate pouring zone, a supply vessel for the metal, a trough extending between the vessel and the mold trains to convey the metal therebetween. The metal is discharged from beneath the surface of the metal in the vessel and into one end of the trough beneath the surface of the metal therein. The other end of the trough is registered with a mold in the trains and moves with the trains while metal is dispensed into the mold from beneath the surface of the metal in the trough. Valves control the discharging and dispensing of the metal to and from the trough. A motor moves the trough, as needed, in the pouring cycle, and a coupler coordinates the movement of the trough and the mold to keep them registered in the pouring zone.Type: GrantFiled: April 28, 1994Date of Patent: March 21, 1995Assignee: General Motors CorporationInventors: Paul N. Crepeau, Gordon A. Tooley, A. Dean Vander Jagt
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Patent number: 5348071Abstract: The apparatus for casting comprises a pressure vessel and a device for pressurizing the vessel. The pressurizing device is in fluidic connection with the vessel. The apparatus is also comprised of a chamber disposed in the pressure vessel within which material is melted. There is a mold adapted to contain a preform disposed in the vessel and in fluidic connection with the chamber by a passage such that melted material in the chamber can be forced down into the mold through the passage as the pressurizing device pressurizes the vessel. A heating device is disposed in the vessel. There is also a device for directionally solidifying the material in the mold. Additionally, there is a method comprising the steps of loading the pressure vessel by disposing a material within the chamber whereby the material is in fluidic connection with the mold adapted to contain a preform through the passage. The passage has a filter disposed therein.Type: GrantFiled: June 15, 1993Date of Patent: September 20, 1994Assignee: PCC Composites, Inc.Inventor: Arnold J. Cook
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Patent number: 5246055Abstract: A vacuum die-casting machine has a bellows forming a sealed enclosure between the rear of the fill chamber and the piston rod. A vacuum is applied to the enclosure during evacuation of the die cavity and charging of the fill chamber with molten metal. As the piston moves forward, an inert gas at about atmospheric pressure is introduced into the enclosure and extends into the feed tube.Type: GrantFiled: September 6, 1991Date of Patent: September 21, 1993Assignee: Aluminum Company of AmericaInventors: James R. Fields, Lawrence W. Cisko, Robert C. Wallace
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Patent number: 5211218Abstract: A melting and casting plant for operation at least under a vacuum and having a vacuum chamber. A wall of the vacuum chamber of the plant is angularly fashioned and is composed of a stationary part and of a swivellable part, the swivellable part being hinged to the stationary part. A door (ingot mold door) is provided in the swivellable part. The shape of the chamber wall and a linking axis of the swivellable part are fashioned or arranged, such that, when the chamber is opened, articles situated in the interior of the chamber are readily accessible. In comparison to the prior art, improved operations of the system, particularly regarding the chamber, is possible.Type: GrantFiled: June 28, 1991Date of Patent: May 18, 1993Assignee: Leybold AktiengesellschaftInventors: Wolfgang Reuter, Josef Gediga