Abstract: A casting chamber configured to form a casting from molten material includes an outer mold, a plurality of inner core elements, and a surface portion of a thermal chill device. The thermal chill device includes first and second interchangeable elements with the surface portion of the thermal chill device including one of a first surface portion of the first interchangeable element and a second surface portion of the second interchangeable element. The first surface portion of the first interchangeable element includes an insulating material and the second surface portion of the second interchangeable element comprising a metallic material.

Abstract: A soluble casting core for forming a cooling channel in a piston has a formed-on part for forming an oil supply opening and a formed-on part for forming an oil drain opening. In order to improve the mechanical strength of the piston, the oil supply opening and the oil drain opening lie in a different pin boss support of the pin bosses of the piston. A third formed-on part, which lies in the circumferential direction and is configured in oblong manner, is disposed between the first formed-on part and the end of the casting core, which part has a shape that narrows conically towards the end of the casting core and forms a continuation of the cooling channel, which narrows conically towards the end of the cooling channel.

Abstract: An improved and efficient method and apparatus for convective cooling of cast sand molds containing molten metal, utilizing vertically-arrayed cooling stations (preferably arranged on a plurality of shelves inside a housing enclosure for temporarily storing said sand molds during their cooling from a molten temperature level to a lower solidification temperature. A draft of cooling air is circulated through said stations in said housing whereby the time for solidifying the molten metal in said cast sand molds is reduced as compared with passive air cooling of said molds. Robot means are provided for moving hot sand molds from a feeding port in said housing to said shelves and for moving cooled sand molds from said shelves to a delivery port in said housing.

Abstract: An investment casting process is provided in which a molten aluminum metal is cast into a refractory mold and thereafter cooled to solidify the metal in the mold. The improvement includes the step of cooling the mold and solidifying the metal therein which is carried out by placing the mold in a chamber adapted to retain a liquid. The mold is mounted in a stationary condition in the chamber. A coolant liquid is introduced into the chamber to immerse the mold in the liquid while maintaining the mold in a stationary condition.

Abstract: In a forming mold equipped with a cooling channel for circulation of a refrigerant composed of a cooling gas and a atomized cooling liquid, any increase of back pressure attributed to evaporation of the refrigerant fed to the cooling channel is inhibited to thereby attain cooling acceleration, and further any occurrence of rust or scale by the refrigerant circulated through the cooling channel is prevented. Accordingly, a channel for supply of the refrigerant to the cooling channel of the forming mold is provided with air pressure source for trapping of air in the supply channel and pressure feeding of the same; oxygen separation means for separation removal of oxygen from the pressure fed air to thereby lower the oxygen concentration of the air; and atomizing means for spraying of the cooling liquid into the air with oxygen concentration lowered.

Abstract: A liquid-cooled permanent chill mold for the continuous casting of metals, including a permanent chill mold plate (2) made of copper or a copper alloy and an adapter plate (3), on which the permanent chill mold plates (2) are fastened via fastening bolts (12). The permanent chill mold plates (3) are coupled to the adapter plates (3) via sheet metal holders (19) situated in their top regions and base regions (20, 21), in addition to via the fastening bolts (12).

Abstract: A cooling system for a low-pressure casting mold is provided, in which a sprue is located at a side surface of a cylinder head to ensure a sufficient distance between a combustion chamber and the sprue so that a combustion chamber cooling system combined with water cooling and air cooling is provided in a lower mold, thus reducing cycle time. Moreover, the cooling system for a low-pressure casting mold improves mechanical properties of a material used by reducing dendrite arm spacing (DAS) and porosity.

Abstract: The invention relates to a method of cooling machines. Typically, the method of cooling is useful in the cooling of dies used in the moulding of plastics or metals. The method relies upon taking advantage of the latent heat of vaporisation of a cooling liquid. A liquid is maintained in a closed chamber in a die such that the liquid is in contact with the surfaces to be cooled and a space above the liquid surface is available. The pressure in the space is adjusted, typically by vacuum equipment, such that the boiling point of the liquid is adjusted to a level which enables the principle cooling process to involve latent heat.

Abstract: A cooling chamber design that increases the heat transfer over conventional designs during the casting process of an aluminum cylinder head.

Abstract: A cooling system for a low pressure casting device, which includes an upper mold provided with a core portion of a spark plug and an upper die, a lower mold provided with a mold portion of a combustion chamber and a lower die, and side molds, may include i) a coolant supply unit connected respectively to the core portion of the spark plug, the upper die, the mold portion of the combustion chamber, and the lower die through coolant supply lines, ii) a cooling air supply unit connected respectively to the side molds and the mold portion of the combustion chamber through air supply lines, and iii) a vacuum intake unit connected respectively to the core portion of the spark plug, the upper die, the mold portion of the combustion chamber, and the lower die through vacuum intake lines.

Abstract: Method and apparatus for improving the quality and mechanical properties of an aluminum alloy engine cylinder block or other large or complex castings by providing sand molds bound with a soluble binder only at locations on said casting from which rapid cooling for directional solidification and/or improved localized mechanical properties are desired with said molds being otherwise bound at the remaining locations only with a more typical insoluble binder.

Abstract: A casting apparatus has a long cooling jig inclined with respect to a vertical direction. A melt is supplied to and flowed on a bottom surface of the cooling jig, whereby a solid phase is generated in the melt to obtain a semi-solid slurry, and the semi-solid slurry is transferred into and solidified in a cavity of a mold to obtain a casting. The casting apparatus further has a release agent application unit, and a release agent is applied by the application unit to the bottom surface of the cooling jig in a direction toward a supply of the melt at an angle of less than 90° to the bottom surface before supplying the melt to the cooling jig.

Abstract: Provided is a crystalliser holding device for billets, blooms and slabs production plants that has a high constructive simplicity, a significantly reduced overall weight and that reduces substantially to zero the need for maintenance. The crystalliser holding device of the invention, in addition to efficaciously guaranteeing the transfer toward the exterior of the heat of the liquid steel introduced into the tubular crystalliser contained therein, also provides a separate circuit for cooling the continuous ingot exiting the crystalliser and the rollers at the foot. It also permits an easy and rapid replacement in the oscillating table in which it is housed.

Abstract: A dual temperature mold assembly for maintaining a mold cavity used in a cast on strap process at two different temperatures facilitates the removal of the solidified strap after the molten metal is solidified. The mold assembly includes a mold cavity having walls attached to different mold assembly segments that are heated or cooled by thermal energy input and coolant processes which can maintain the mold cavities at different temperatures, so that molten metal around the battery plate lugs in a mold cavity segment is solidified while the sides of the mold cavity are exposed to at least one adjacent heated segment to provide thermal energy thereinto, resulting in a reduction of the amount of molten metal necessary for a cast on strap, and reducing the amount of thermal energy input into the process for manufacturing the straps.

Abstract: A method for designing the location, surface temperature, flow rate, length and type of cooling lines within a mold for a casting process. The method allows the user to optimize each value for each individual cooling line of the mold. The method can utilize one or more parameters of the casting process and the heat load to be carried by each of the cooling lines in designing the mold.

Abstract: A casting chamber configured to form a casting from molten material includes an outer mold, a plurality of inner core elements, and a surface portion of a thermal chill device. The thermal chill device includes first and second interchangeable elements with the surface portion of the thermal chill device including one of a first surface portion of the first interchangeable element and a second surface portion of the second interchangeable element. The first surface portion of the first interchangeable element includes an insulating material and the second surface portion of the second interchangeable element comprising a metallic material.

Abstract: A method of providing a mould with a conformal cooling passage includes rough machining a mould cavity generally corresponding to a moulded part shape using CAD data. Conformal cooling slots are cut in the mould cavity using the CAD data. The conformal cooling slots are welded shut using the CAD data to provide conformal cooling passages. A class A surface is machined over the conformal cooling passage and corresponds to a finished mould part shape using the CAD data.

Abstract: A casting process and apparatus for producing directionally-solidified castings, and castings produced therewith. The process entails applying a facecoat slurry to a surface within a mold cavity to form a continuous solid facecoat on the surface, introducing a molten metal alloy into the mold cavity so that the molten metal alloy contacts the facecoat, and then immersing the mold in a liquid coolant to cool and solidify the molten metal alloy and form a casting of the metal alloy, during which an oxide layer forms on the casting surface. The facecoat is sufficiently adherent to the oxide layer such that at least a portion of the facecoat detaches from the mold surface and remains tightly adhered to the casting surface in the event the casting contracts during cooling. The facecoat contains at least 60 weight percent of a first phase of yttria, and the balance of the facecoat is a binder phase of an inorganic material.

Abstract: An improved apparatus for direct chill casting of metals includes a mold, a bottom block assembly and a coolant. The mold is configured to surround a molten metal with a mold wall and the mold wall has an outer surface and an inner surface being in contact with the molten metal. The bottom block assembly is arranged at the bottom of the mold and includes a direct chill casting block configured to move away from the mold as the casting forms a solidifying shell of the molten metal. The coolant surrounds the outer surface of the mold wall and is arranged to remove heat away from the molten metal via the inner surface of the mold wall. The outer surface of the mold wall has a circumferential groove filled with a brazing alloy.

Abstract: Tooling systems including a mandrel for receiving, and providing shape to, a metallic deposit applied using a high temperature additive manufacturing device; a metallic cladding applied to the mandrel for reducing contamination of the metallic deposit; and at least one cooling channel associated with the mandrel for removing heat from the system.

Abstract: A process is provided for manufacturing aluminum vehicle wheels by a casting process that is followed by processing including flow forming and heat treatment steps while one or more risers remain on the cast wheel blank. The process can include directing cooling fluid onto an exposed surface of the casting mold to enhance wheel strength. One-by-one transfer of wheel blanks can be practiced to avoid negative aspects of batch processing.

Abstract: A pouring method and a device in a vacuum sealed process to produce a thin-wall cast by using a mold framing for the a vacuum sealed process, and a as-cast product using the pouring method are provided.

Abstract: A method and apparatus are provided for producing an amorphous ribbon by ejecting and rapidly solidifying molten alloy on a circumferential surface of a rapidly rotating cooling roll, wherein the cooling roll is polished online during amorphous ribbon production. When the circumferential surface of the cooling roll after peeling off the ribbon is polished using a polishing member, the circumferential surface of the cooling roll is polished continuously or intermittently across its lateral direction while differentiating the polishing mode in accordance with the surface properties.

Abstract: A sand based mold and method for casting a device having a cavity. The sand based mold includes a core part including grains of sand bonded with a resin, where a shape of the core part fits a shape of the cavity of the device, and a first pipe embedded into the core part and configured to allow a compressed fluid to flow through the first pipe during a solidification process of the device, the first pipe having an inlet and an outlet that exit the mold.

Abstract: A method and apparatus is disclosed for sequentially direct chill casting a composite ingot made of metals having similar freezing ranges. Poor adhesion between the layers and low reliability of casting are addressed by adjusting the position of secondary cooling (created by applying water streams to the emerging ingot) relative to the upper surfaces of the molten metal pools compared to the conventional positions of first application of the secondary cooling. This can be achieved by moving one or more walls of the mold (when the secondary cooling emanates from the bottom of such walls), or adjusting the height of the molten metal pools within the mold and moving cooled divider walls between the pools. The relative temperatures and conditions of the metals at positions where they meet at the metal interface may therefore be optimized.

Abstract: Method and apparatus for improving the quality and mechanical properties of an aluminum alloy engine cylinder block or other large or complex castings by providing sand molds bound with a soluble binder only at locations on said casting from which rapid cooling for directional solidification and/or improved localized mechanical properties are desired with said molds being otherwise bound at the remaining locations only with a more typical insoluble binder.

Abstract: In a forming mold equipped with a cooling channel for circulation of a refrigerant composed of a cooling gas and a atomized cooling liquid, any increase of back pressure attributed to evaporation of the refrigerant fed to the cooling channel is inhibited to thereby attain cooling acceleration, and further any occurrence of rust or scale by the refrigerant circulated through the cooling channel is prevented. Accordingly, a channel for supply of the refrigerant to the cooling channel of the forming mold is provided with air pressure source for trapping of air in the supply channel and pressure feeding of the same; oxygen separation means for separation removal of oxygen from the pressure fed air to thereby lower the oxygen concentration of the air; and atomizing means for spraying of the cooling liquid into the air with oxygen concentration lowered.

Abstract: The exemplary embodiments relate to the removal of cooling water used to cool the surface of an ingot as it is formed during casting. The cooling water is removed from the surface by directing jets of water onto the surface at an angle, and with a momentum, that causes the cooling water to be stripped from the surface when contacted with the jets, and to follow a path that prevents the cooling water from again coming into contact with the ingot surface at a position beyond the point of removal. The apparatus for this includes nozzles to create the water jets, and equipment for supplying water under sufficient pressure and rate of flow to the nozzles.

Abstract: The invention relates to a method and equipment for cooling anodes (4) in connection with anode casting (1), so that in the cooling unit (5), in between cooling steps, water is removed from the anode surface at least once before removing the anode (4) from the cooling unit (5).

Abstract: A crystallizer and method for casting using the crystallizer. The crystallizer mainly includes a plurality of-position-limiting parts (16) on the inner side of the mould seat (6, 7). The inner side of the position-limiting parts (16) is in correspondence with the external periphery of the mould wall (8-1, 9-1) of the film mould (8, 9). A medium channel (17) with a medium-supplying port (5) at its upper end is formed between the adjacent position-limiting parts (16).

Abstract: In the case of a one-piece lost mould for metal castings 4 of a set moulding material which encloses a mould cavity and has at least one metallic cooling channel 6 that is embedded in the moulding material and carries a cooling medium, portions of the outer side of the metallic cooling channel 6 are uncovered and/or only slightly covered by the moulding material in the direction of the mould cavity.

Abstract: Crystalliser holding device for billets, blooms and slabs production plants that has a high constructive simplicity, a significantly reduced overall weight and that reduces substantially to zero the need for maintenance. The crystalliser holding device of the invention, in addition to efficaciously guaranteeing the transfer toward the exterior of the heat of the liquid steel introduced into the tubular crystalliser contained therein, also provides a separate circuit for cooling the continuous ingot exiting the crystalliser and the rollers at the foot. It also permits an easy and rapid replacement in the oscillating table in which it is housed.

Abstract: A temperable member manufacturable in a low cost and flexible manner to make possible a locally discriminating tempering process. The temperable member is formed from at least two modules joined to each other. At least one of the modules is formed as a one-piece element, and at least another element is a tempering module. The tempering module is formed from plate-shaped elements arranged on top of each other and forming a stepped outer marginal contour. The one-piece element includes a housing which is complementary to the contour. At least one channel is formed inside the tempering module.

Abstract: An aluminum ingot casting machine comprising a source of molten metal, a rotatable annular ring, carrying ingot casting moulds and a drive means for indexing the moulds. The machine includes a vacuum demoulder having a vacuum seal arrangement comprising a sealing element having a flexible core which can deform to form a vacuum seal against an ingot and a flexible abrasion resistant outer layer on said core, and retaining elements located on a lower face of the vacuum lifting head for releasably retaining the sealing element onto the lifting head. The vacuum seal comprises a flexible ring shaped body, being rounded in cross section, having a fiber cord core and an abrasion resistant flexible sheathing surrounding the core.

Abstract: Molten metal is injected uniformly into a horizontal mold from a feed chamber in a horizontal or vertical direction at a controlled rate, directly on top of the metal already within the mold. A cooling medium is applied to the bottom surface of the mold, with the type and flow rate of the cooling medium being varied to produce a controlled cooling rate throughout the casting process. The rate of introduction of molten metal and the flow rate of the cooling medium are both controlled to produce a relatively uniform solidification rate within the mold, thereby producing a uniform microstructure throughout the casting, and low stresses throughout the casting.

Abstract: 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.

Abstract: The invention relates to a continuous casting mould for liquid metals, especially for liquid steel, comprising steel charging plates (2) which are surrounded by water reservoirs (1), cassette-type copper plates (3) arranged against the same, end plates (7), if needed, for the thickness and/or the width of the cast billet, and coolant channels (9). The aim of the invention is to take measures to counteract the high temperatures in the meniscus region (13) using appropriate embodiments of the copper plates (3) and/or the steel charging plates (2). To this end, the thickness (10) of the copper plates (3) between the coolant (11) and the hot side (3a) of the copper plates varies along the width (2×L) and/or in terms of the height (12).

Abstract: A block for use in a die casting or molding system receives manufacturing material for distribution into a runner system of a die or mold and cooling fluid for transferring heat away from the block. The block comprises a single-piece body and a plurality of cooling bores. The single-piece body includes features for distributing the manufacturing material, and has a first face, a second face and a plurality of side surfaces disposed between the first face and second face. The plurality of bores are positioned between the side faces and form cooling channels for receiving the cooling fluid.

Abstract: An arrangement for forcing rapid localized directional solidification, or global homogenous accelerated solidification of a liquid or semi-solid parent material, which is contained by a media mold that possesses porous properties. The process produces solidified matrix structures and cast properties in the parent material otherwise not possible through conventional solidification methods under ambient conditions. The process is capable of enhancing ordinary production cycles by reducing the overall cycle time required to produce a normally solidified material in a porous media mold.

Abstract: A system and method for thermal management of a die is disclosed wherein cooling of the die is controlled by controlling coolant flow to switch between laminar flow and turbulent flow as desired.

Abstract: A cooling mold (262) includes a cooling portion (2632), and defines a channel. The cooling portion has a number of intersecting grooves (2636). The channel communicates with at least one of the grooves. The channel and the grooves are configured for gas to flow therethrough to a workpiece at least partly received in the cooling portion.

Abstract: A mold includes ducts designed to be traveled by heat-regulating fluid of the mold. The ducts are realized by grooves realized on the external surface of the mold and closed above along their extension by metallic strips. Advantageously the grooves are formed by pairs of ribs projecting from the surface of the mold to form side walls of the ducts.

Abstract: An arrangement to assist in heat transfer through a mold for applications such as injection molding of plastics material including at least one closed chamber within the mold, the chamber being only partially filled with liquid and a remainder of the chamber being filled with substantially only vapor of the liquid within the chamber, at least a portion of the chamber being positioned to transmit heat from a targeted location of the mold into liquid within the chamber, and condensing means adapted by reason of heat exchange to effect condensation of vapor within the chamber, the mold being arranged in that the liquid such as water is arranged to be held in the chamber in such a way that the liquid will be distributed to reach or be held at different heights within the chamber. This is achieved in one case by the addition of a foaming agent in the liquid. In another case by having a flock attached to the inner surface of the chamber.

Abstract: While a die cast product is produced by a die casting method, an overheated portion of a low pressure die casting metallic pattern is effectively cooled by circulating a cool air and/or a coolant. Therefore, a solidification period of a molten metal in a cavity is minimized, and a quality of products and a durability of the metallic pattern are improved.

Abstract: A runner cooling block for use in a die casting system comprises a spreader block, a spreader, a bushing block, a sprue bushing and a water jacket. The sprue bushing comprises a sprue channel running through an interior of the sprue bushing and a cooling channel running circumferentially around an exterior surface of the sprue. The sprue bushing, water jacket and bushing block are assembled to allow cooling water to pass through the cooling channel. The spreader block and the bushing block are assembled such that the spreader is centrally located within the sprue channel wherein molten metal is allowed to pass through the sprue channel for passage into the runner system. The cooling channel includes at least one circumferential heat transfer contour to provide increased heat dissipation to enhance cooling of the molten metal passing through the sprue channel.

Abstract: A molten magnesium material is filled into a product section of a die. The molten magnesium material is cooled and solidified in the die, so that a molded product is formed. Subsequently, a thread-shaped pin is rotated, so that a female-thread forming section is drawn from the female-thread section of the molded product while the female-thread forming section is rotated. Thus, the female-thread section can be formed when the molded product is formed. A magnesium-alloy material is not apt to stick to a steel material used in the die compared with an aluminum-alloy material, so that the female-thread section can be steadily formed.

Abstract: A cooling arrangement for the rolling stand of a continuous casting system for heavy supports is provided with spraying nozzles which can be acted upon by cooling liquid and compressed air through supply pipes laid laterally in a longitudinal direction of the rolling stand. Only two supply pipes for cooling liquid and compressed air respectively are assigned to each side of the rolling stand. The supply pipes are laid parallel to one another and are equipped with connection flanges on which connection plates can be mounted in a simple manner and, in turn, are fixedly connected with spraying nozzles. This further development permits a simple mounting and demounting of the spraying nozzles and ensures a precise alignment of the spraying jets with respect to the billet to be processed.

Abstract: The invention relates to an injection mould (1) for producing three-dimensional components. The mould has a system (2) for mould tempering having at least one groove (12) which is arbitrarily extended between two points in the available volume of the mould for conducting a tempering medium which is intended for tempering of modules (4, 8) included in the mould (1). Each groove (12) is along essentially its entire extent covered by a cover (15). The invention also concerns such a system (2) for mould tempering of injection moulds (1), as well as an injection moulding assembly comprising such an injection mould (1).

Abstract: A mold cooling device includes an air feeding and discharging circuit 22 which effects the driving by air of a pump section 1 for feeding a cooling liquid to a fluid flaw passageway 65a fanned in a mold 64 and the feeding of air to the fluid flow passageway 65a. Letting (Dx) be the outer diameter-corresponding dimension of the holed convex portion 53x of a cast article 64x, (D1) be the outer diameter of the pin section 65 of the mold 64, (t1) be the outer peripheral thickness of the pin section 65, and (T1) be −5.103+(0.621×Dx)−(1.068×D1)+(3.61×t1), the time (T) for feeding cooling liquid to the fluid flow passageway 65a after completion of the pouring of molten metal into the mold 64 is set so that the relation T1-0.5 seconds ≦T≦T1×0.5 seconds is satisfied.

Abstract: A plug for sealing and resealing the passages for heating and cooling liquid in a casting mold. The plug includes a stainless steel socket head NPT plug which is screwed into the passage to seal it. Inboard of the plug there is mounted a resilient expandable silicone tubular element that is expanded by squeezing it to further seal the passage.