Abstract: A core for casting a blade of a turbomachine, the core including a first part for defining a first cavity and a second part of which at least one portion defines a second cavity located between the first cavity and the tip of the blade. The portion of the second part includes a through-hole that ends opposite the first part so as to define, in the cast blade, an outer face of a duct for removing dust from the first cavity. An alumina pin which is secured to the end face of the first part extends into the through-hole to define the inner face of the duct. A centering sheath placed between the pin and the through-hole centers the pin in relation to the through-hole. The centering sheath is made of a material that is intended to dissolve before the blade is cast around the core.

Abstract: A method for casting an article comprises a first region and a second region. The method comprises casting an alloy in a shell, the shell having a casting core protruding from a first metal piece; and deshelling and decoring to remove the shell and core and leave the first region formed by the first piece and the second region formed by the casted alloy.

Abstract: A method of manufacturing a side frame mold for casting a side frame of a railway car truck includes forming a drag and a cope portion of a mold from a casting material to define an exterior surface of a drag portion and cope portion, respectively, of the side frame. The mold includes a portion for casting the pedestal jaw of the side frame. The drag and the cope portions are then cured.

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: Disclosed is both a process and apparatus for forming a molded article. The molded article is formed in a vertically potted flaskless mold. The flaskless mold is closed having an opening in the top portion that receives a chill for directing the cooling of the molten metal introduced into the mold cavity. After the molten metal solidifies and before the mold is broken down, the chill is removed for reuse in the process.

Abstract: The present invention relates to casting and more particularly to an improved apparatus and method of aluminum casting. The casting system 10 includes a furnace 12, a pump 14 and a mold 16. A semi-permanent mold cope 30 is mounted to the top of the mold 16 to quickly cool the adjacent portion of the casting 20. The semi-permanent mold cope 30 is movable with respect to the mold so that it can be moved between an open and closed position. The mold 16 can be brought to the semi-permanent mold cope 30 when the semi-permanent mold cope 30 is open and the semi-permanent mold cope 30 can then be closed onto the casting 20. The molten metal is then pumped into the mold 16 with the semi-permanent mold cope 30 in place. A laser 34 monitors the rate of mold fill by monitoring the fill rate of the riser 28.

Abstract: A mould structure for producing metal castings by solidifying molten metal, in particular for producing a light-alloy engine crank-case, which includes a plurality of cores defining a mould cavity and a primary inlet aperture for feeding the molten metal into the bottom region of the mould cavity through the walls of one of the said cores, which includes: a metal containment structure, open at the top, with a bottom wall and side walls having a plurality of reference elements which have surface portions which complement surface portions of the said cores, the said cores being assembled inside the containment structure so that they are engaged with each other and with the said reference elements, and being shaped so as to define interstices between their surfaces facing outwardly of the mould cavity and the walls of the containment structure; and at least one cover element made of a highly heat-conductive material, supported by the side walls of the containment structure and by some of the said cores and servi

Abstract: A compact stacked mold is provided by reducing the sand-metal ratio. Cavities (11, 12) are formed on upper and lower sides (13, 14) of a chill plate (10) corresponding to one half of a cam profile, and the upper and lower sides (13, 14) are aligned with parting surfaces of a mold (15).

Abstract: A apparatus casting a turbine wheel of a metal alloy, wherein there is generated a columnar grain structure parallel to the leading and trailing edges of the vanes, by directional solidification of the metal from the central aperture in the wheel outward to the vane tips. A form with cavity to receive therein the molten metal has a thin walled core in the center, with the core wall outer surface in place to provide one wall of the cavity. A heat transfer medium in fluid form is circulated through the core, thereby cooling the poured metal by heat transfer from the inner ends of the vanes outward to the tips.

Abstract: A mold and method for making castings having variable hardness is disclosed. The mold assembly includes a cope and drag captured between a pair of carrier plates. Chill members depend from the carrier plates and are received in appropriate apertures formed in the cope and drag. The chill members are inserted into the cope and drag after formation thereof and are removed therefrom prior to shake-out of the molded article. The chill members are used to control the cooling of the molded article.

Abstract: The mould assembly comprises mould segments of generally non-thermally conductive material which define a mould cavity for receiving liquid metal through at least one in-gate. A thermal extraction member of a high thermally conductive material contacts a portion of the mould cavity through which heat can be extracted rapidly to establish positive thermal gradients in the casting and thereby promote directional solidification. The mould assembly is also provided with a seal to selectively isolate the mould assembly from the liquid metal source to allow the mould assembly to be removed from the casting station to the cooling station before any substantial solidification has occurred, providing a more efficient use of the casting station.

Abstract: A permanent metal mold (12) has a casting cavity (18) within which variable thickness molten metal articles (20) are cast. Portions (26) of the casting cavity walls (16) are formed oversized and lined with sand (44) to conform with the external size and shape of certain thick (46) and thin (48) sections of the cast article (20). The thickness of the sand liner (44) is reversely correlated to the thick (46) and thin (48) sections of the article (20) to cause these sections (46, 48) to cool at different rates in order to achieve an approximately equalized cooling time of these sections (46, 48). Other portions (50, 52) of the casting cavity walls (16) are formed bare of the sand liner (44) and conform with the external size and shape of other corresponding sections (54, 56) of the cast article (20).

Abstract: Molten metal is cast in a cavity formed within a permanent, metal mold. The major portion of the cavity is lined with a sand liner whose thickness is reversely correlated to the thickness of the integral sections of a varying thickness cast metal article. However, portions of the metal cavity are bare and such portions form a part of the interior casting surface defined by the sand liner. Thus, the cast metal contacting the bare metal portions of the mold uniformly and rapidly chills to produce harder surface areas on the finished cast article, while the remaining portions of the cast article tend to cool at a generally equalized cooling rate corresponding reversely to the thickness of the sand liner. A vacuum is applied to the casting cavity during filling with molten metal for rapidly filling the sand lined cavity and insuring complete contact between the molten metal and the bare metal portions of the casting cavity.

Abstract: An improved apparatus and method is used to cast a plurality of articles in a mold structure having a plurality of article molds disposed in an array having an open central portion. The article molds are filled with molten metal while the mold structure is supported on a chill plate. An inner baffle plate is disposed in the central portion of the array of article molds and retards the transfer of heat from the article molds to the chill plate. The inner baffle plate is supported by a support structure which extends through the chill plate. After the article molds have been filled with molten metal, the chill plate and mold structure are lowered relative to the inner baffle plate to increase the rate of heat transfer from the article molds to the chill plate through the open central portion of the array of article molds. Thereafter, the inner baffle plate and support structure are lowered with the chill plate and mold structure.

Abstract: A mold structure has a plurality of article molds disposed in an array with an open central space. A gating system is connected with upper ends of the article molds and a base is connected with lower ends of the article molds. A baffle plate is inserted into the open central space between the article molds. The baffle plate has an area which is greater than the area of an opening in the base. A lower side of the baffle plate overlies an area on the base which extends completely around the opening in the base. To insert the baffle plate through the opening in the base, a slit is formed in the baffle plate. A portion of the base is received in the slit and then the baffle plate is rotated to turn it through the opening in the base. An alternative method of inserting the baffle plate is by partially folding the baffle plate and inserting the folded baffle plate through the opening in the base of the mold structure.

Abstract: A chill device for combination with a vaporizable pattern for casting metal by a lost foam process comprises a chill body receivable within a bore of the pattern and including a plurality of outwardly extending fins. The fins define channels therebetween for packing with mold sand to shape the cast metal and for venting pattern decomposition vapors during casting to avoid pore-forming entrapment in the cast metal. Also, the fins contact the bore surface to conduct heat into the chill body from the cast metal about the bore to accelerate solidification and thereby reduce shrink porosity. Thus, the chill device of this invention produces pore-free metal in the casting region immediately about the bore.

Abstract: An improved mold includes an upper mold section having a primary distribution system which is connected with a furnace and a lower mold section which is withdrawn from the furnace on a chill plate. A baffle plate is supported from the primary distribution system. The lower mold section includes a secondary distribution system which is connected in fluid communication with the primary distribution system at separable joints. The secondary distribution system is connected in fluid communication with article molds which are disposed in an annular array. During pouring of molten metal, reaction forces are transmitted to the chill plate from the pour cup through a support post and baffle plate. Once the article molds have been filled with molten metal, the chill plate is lowered. The primary distribution system which is connected to the furnace, remains stationary.

Abstract: A method and ceramic mold structure for use in producing articles having a predetermined crystalline orientation such as single crystals. The technique involves the use of a ceramic mold mounted on a chill plate with the mold defining a cavity tilted at an angle between about 5.degree. and 75.degree. relative to the vertical. One or more seed crystals are supported adjacent the chill plate and the orientation of the crystal is selected to provide a desired orientation in the resulting casting. The method results in improved solidification control, particularly with reference to avoiding defects caused by shrinkage.

Abstract: An apparatus for producing directionally solidified castings wherein a mold having an open bottom is supported on a chill plate with metal poured into the mold initially solidifying adjacent the chill plate and thereafter progressively solidifying away from the chill plate. The chill plate is provided with a plug member, and the metal being cast initially solidifies around this plug member whereby the metal is securely held in intimate contact with the plug member and adjacent chill plate surfaces so that the withdrawal of heat from the casting through the chill plate is greatly facilitated.