Abstract: The present invention relates to a non-crushing casting system including mold units for receiving a molten material from a melting furnace and casting the molten material to form a plurality of unit shape materials having a predetermined size; and a conveyor unit for performing infinite looping of mold units to detach the unit shape materials of the cast molten material, and for conveying and discharging the detached unit shape materials. According to the present invention, to manufacture a subsidiary raw material for steel manufacture having a certain unit size, ferromanganese or ferrosilicon is melted, and then cast in molds having a predetermined size.

Abstract: A mold-forming assembly for forming chemical set sand into a plurality of mold portions for one or more objects to be cast in the mold portions. The assembly includes a loading subassembly for forming the mold portions, a positioning subassembly for positioning each mold portion in a predetermined position, and a conveyor subassembly extending between the loading and positioning subassemblies, for moving the mold portions from the loading subassembly to the positioning subassembly.

Abstract: A two tiered mold handling system for use in a sand mold casting machine which comprises a two tiered conveyor for pouring and cooling, or a two tiered conveyor for cooling only. The two-tiered conveyor has an upper linear track and a lower linear track disposed at a lower vertical elevation. The tracks carry a plurality of mold pallets along an endless path around the upper and lower linear tracks. The application is directed toward several concepts including two tiered pouring conveyors in combination with two tiered cooling conveyors, two tiered combination pouring and cooling conveyors, and one tiered pouring conveyors in combination with two tiered cooling conveyors to provide a lower pouring elevation.

Abstract: A two tiered mold handling system for use in a sand mold casting machine which comprises a two tiered conveyor for pouring and cooling, or a two tiered conveyor for cooling only. The two-tiered conveyor has an upper linear track and a lower linear track disposed at a lower vertical elevation. The tracks carry a plurality of mold pallets along an endless path around the upper and lower linear tracks. The application is directed toward several concepts including two tiered pouring conveyors in combination with two tiered cooling conveyors, two tiered combination pouring and cooling conveyors, and one tiered pouring conveyors in combination with two tiered cooling conveyors to provide a lower pouring elevation.

Abstract: A conveyor for a molding machine and a molding machine incorporating the conveyor in which the portion of the conveyor and its driven rollers that run through the pouring station have been shortened such that the pallets extend over the conveyor to shield the conveyor and rollers from molten metal, and in which the rollers are slanted at an oblique angle relative to the intended path of the molds such that the driven rollers bias the pallets away from the pouring line to ensure that pallets carrying molds do not fall off the conveyor onto the pouring line.

Abstract: A casting process for casting, in particular of sand molds provided with casting boxes, which makes it possible to keep the apparatus expense low, to save cycle material and to achieve an improved quality, consists of the intake channel extending in a plane lying essentially horizontally during casting and being provided with a bearing surface defining its port, onto which bearing surface can be sealingly positioned a fill pipeline through which the mold can be filled with metal under low pressure. A casting system to carry out the method consists of a casting machine with a pressure kettle and a fill pipeline which is connected to the intake channel lying essentially in a horizontal plane, whereby the sealed coupling of fill pipeline and intake channel is obtained through specified bearing pressure.

Abstract: An offset conveyor system utilizes a lower conveying section positioned adjacent a pouring station where molten metal is poured into weighted and jacketed sand molds. Molds are transported on carriers along the lower section from a mold loading station to a weight and jacket placement station to the pouring station. After pouring, the carrier with jacketed mold is moved up an incline to an upper conveying section parallel the lower section and may overlap the lower section partially. Molds are transported in an opposite linear direction relative to the lower section to a weight and jacket removal station and to a mold dump station, where the sand mold and casting are removed from the conveyor. The carrier is returned to the lower conveyor section to receive another mold. The weight and jacket removed from the upper section is placed on a mold on the lower section, therefore only a minimum number of weights and jackets are used.

Abstract: A casting process for casting, in particular of sand molds provided with casting boxes, which makes it possible to keep the apparatus expense low, to save cycle material and to achieve an improved quality, consists of the intake channel extending in a plane lying essentially horizontally during casting and being provided with a bearing surface defining its port, onto which bearing surface can be sealingly positioned a fill pipeline through which the mold can be filled with metal under low pressure. A casting system to carry out the method consists of a casting machine with a pressure kettle and a fill pipeline which is connected to the intake channel lying essentially in a horizontal plane, whereby the sealed coupling of fill pipeline and intake channel is obtained through specified bearing pressure.

Abstract: A mold handling system for transferring molds from multiple feed lines to a single main conveyor. The present invention provides an improved and simplified system for transferring molds from several mold making machines to a single conveyor leading to a pouring station. Through the use of a transfer conveyor with cantilevered arms which intersect with the feed lines and the main line, molds can be transferred from the transfer conveyor to the main line by raising and lowering the cantilevered arms. A simplified mechanism for raising and lowering the transfer conveyor is provided in the form of an air actuated bellows apparatus. In order to provide lateral support to the transfer conveyor, brackets flank the bellows that are provided with a predetermined amount of lateral play to provide both the lateral support to the transfer conveyor, as well as enable the transfer conveyor to be raised and lowered.

Abstract: 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.

Abstract: An apparatus for the continuous sequential casting of metals and their alloys wherein a furnace is rotated about an axis and a series of molds is continuously transported to the furnace and the molds are sequentially filled with molten metal poured from the furnace. Each of the molds is caused to move in synchronous arcuate motion with an outlet of the furnace directly above the mold, so that the mold may be filled with metal from the furnace during the synchronous motion thereof. Within the furnace, a central main chamber communicates with the respective chamber of each of the outlets, such that, a continuous circuit of molten metal is maintained between the main and outlet chambers. In the top portion of the main chamber, an annular opening allows the addition of charge to the furnace during the rotation thereof for the continuous sequential casting process. During the filling of the molds, metal is withdrawn from the furnace substantially below the slag therein to prevent slag from entering the molds.

Abstract: A method and apparatus is disclosed to increase the line speed in a permanent mold casting system by eliminating the acceleration and stopping of a shuttle car system to remove mold wagons from the system by means of a continuous chain drive for the system and the use of a single shuttle car in combination with a chain release means eject a mold wagon from the return line to a wagon storage line of the system.

Abstract: An ingot casting apparatus having an open top ingot moulds hinged to an endless hauling chain of a conveyer. The conveyer is inclined so that the upper descending branch of the endless chain with the ingot moulds placed thereon is inclined to the horizontal at an angle of 30.degree.-60.degree. . Each ingot mould is formed by a bottom, two longitudinal walls and a single transverse wall. The transverse wall of each ingot mould is provided with an opening for passage of the molten metal. With such an arrangement the cavities of the ingot moulds communicate with one another by means of openings provided in the transverse wall of each ingot mould. Mounted above the ingot moulds arranged on the upper descending branch of the endless chain of the conveyer, below the zone where the molten metal is poured into the ingot moulds, is a water-cooled plate adjoining tightly to the top ribs of the walls of the ingot moulds passing under the plate after the molten metal has been poured into them.

Abstract: A foundry for automatically making sand castings, in which a metal casting and sand cake are transferred to a container after partial cooling and are carried with the container to a storage zone to cool for a time independent of any restrictions imposed by the conveying path, conveying speed, or cooling time required by other castings being processed. During handling and cooling, the integrity of the sand cake about the casting is maintained to provide cooling characteristics desirable for complex castings with variations in wall thickness. Specific structures handle and convey the sand cake and casting efficiently and reliably. Associated structure fabricates the sand molds and pours the castings, all in a continuous process.

Abstract: A foundry casting machine comprising an endless conveyor supported on a frame within an overall casing for movement in a vertical plane through a sinuous path, the casing having a first opening therein so that trays supported by the conveyor, as they move past said first opening can have moulds assembled thereon, a second opening in the casing at a pouring station to enable molten metal to be poured into the moulds and a third opening in the casing through which the contents of the trays may be removed, air extraction means for withdrawing undesirable gases and air-borne particles from the interior of the casing and means to hold together the parts of the mould prior to the pouring of the molten metal, said means comprising either one or more weights which are automatically placed upon the moulds prior to a pouring operation and are removed from the moulds subsequent to the pouring operation or clamping devices supported on the trays, the clamping devices being suitable either for clamping together mould part

Abstract: A plurality of conveyorized molds, having nugget cavities which are deep compared to their width, are passed beneath a continuously pouring stream of non-ferrous molten metal at a rate of speed such that the cavities are only partially filled to prevent bridging over and freezing together of nuggets in consecutive cavities. Bridging over is further prevented by providing a knife edge surface between consecutive cavities wherein the stream is split between said cavities in such a manner that it is received substantially all within the mold cavities, there being little or no accumulation of metal on the surface of the mold cavities. This apparatus and method of pouring minimizes wetting of the vertical wall portions of the cavities, whereby uniformly shaped nuggets are formed without attendant formation of undesirable risers, sprues or tails which cannot be easily or inexpensively removed from the nuggets.