Abstract: A hybrid core for manufacturing a cast component, the hybrid core including a sand core portion having an exterior shape configured to define an interior feature of the cast component. The hybrid core also includes a metal chill element embedded within the sand core portion. The metal chill element is configured to locally absorb heat energy from the cast component during cooling of the cast component and solidification thereof. The metal chill element is constructed and arranged within the sand core portion to be removed during shake out from the cast component subsequent to the solidification thereof. A system and a method for manufacturing a cast component using such a hybrid core are also envisioned.

Abstract: A method for manufacturing a railcar coupler knuckle includes, before casting, positioning an external chill within a cope mold portion and a drag mold portion offset from and adjacent internal walls of a pulling face and a throat of the cope and drag mold portions, thus producing a casting with reduced micro-shrinkage in at least the throat, a high-stress section of the casting. Use of subsurface chills produces an improved surface with fewer inclusions when compared to an equivalent surface produced in a process without use of a subsurface chill. The external chill may be a cone chill of a larger size to improve cooling and solidification at and below the surface. The external chill may also be a cylindrical and/or oblong chill with a tapered design that may correspond to the internal walls of the cope and drag mold portions between the pulling face and the throat.

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 horizontal continuous casting apparatus for continuously manufacturing a magnesium alloy plate and a method of manufacturing a magnesium alloy plate using the same. The horizontal continuous casting apparatus is structured such that the cross-sectional area of the plate is equal to or smaller than that of a melt inlet, and includes a cooling unit for indirectly cooling the melt using a cooling jacket provided to the outer wall of the mold and/or for directly cooling the melt through spraying of cooling water, and a drawing unit having a multi-step drawing cycle. Thereby, magnesium alloy plates having various sizes can be safely and continuously cast.

Abstract: A mold design is disclosed for precision sand casting of engine cylinder blocks, such as engine cylinder V-blocks, having chills disposed therein, wherein an expansion and contraction caused by changes in temperature during the casting operation are accommodated by the chills.

Abstract: A chill assembly for chilling a molten material during formation of a part is disclosed. The chill assembly includes an upper platform and a mold platform for receiving a mold package to be filled with the molten material to form the part. The upper platform has a first platen moveable in a vertical direction relative to the molding platform. A plurality of chills are moveably supported by the first platen for quenching the molten material. Each of the chills are moveable between a pre-chill position and a post-chill position. An alignment sub-assembly engages the chills and aligns the chills in the pre-chill position. The alignment sub-assembly re-aligns the chills after the chills have quenched the molten material and moved to the post-chill position. The alignment sub-assembly is capable of precisely aligning and re-aligning the chills after each successive quenching of the molten material.

Abstract: A chill assembly for chilling a molten material during formation of a part is disclosed. The chill assembly includes an upper platform and a mold platform for receiving a mold package to be filled with the molten material to form the part. The upper platform has a first platen moveable in a vertical direction relative to the molding platform. A plurality of chills are moveably supported by the first platen for quenching the molten material. Each of the chills are moveable between a pre-chill position and a post-chill position. An alignment sub-assembly engages the chills and aligns the chills in the pre-chill position. The alignment sub-assembly re-aligns the chills after the chills have quenched the molten material and moved to the post-chill position. The alignment sub-assembly is capable of precisely aligning and re-aligning the chills after each successive quenching of the molten material.

Abstract: cooling unit for use in sand molds where casting parts are obtained. The coolers consist of several modules (5) mounted on a support (4) with a certain clearance, and attached to it by a bar (7), being placed on a pallet (3) handled by robotic means and displaceable within a casting installation together with an upper pallet (1) in which the mold is placed, which is superimposed and coupled on the lower pallet (3) in the automated assembly of the mold on the cooling unit, the mold being automatically disassembled from the cooling unit after the cast part (P) is obtained. Each cooler module (5) can consist of a single part, two parts (5′) or three parts (5″), and it is mounted on the corresponding support (4) with a clearance (6) in order to absorb the expansions and contraction caused by the heat transmitted by the molten metal.

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: The system of coolers is foreseen for its use in sand moulds in which cast pieces are obtained. The coolers are constituted by several units or modules (5) which are mounted in a support (4), with certain play and are fastened to this by means of a bar (7), forming a multiple cooler that, arranged on a pallet (3) on which in turn is superimposed a support pallet (1) of the mould, allows the displacement of the whole in the casting production line. That is, the assembly of the multiple cooler on the mould, as well as its extraction and separation with regard to the casting that is obtained, is carried out in an automatic way. Each unit or module (5) of the cooler is capable of being constituted by a single piece, by two pieces (5′) or by three pieces (5″), and assembly thereof on the corresponding support (4) will be carried out with play (6) to absorb the expansions and contractions caused by the heat transmitted by the molten metal.

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 retractable metal insert assembly for a core sand mold having at least one sand core element provided with walls to define an opening communicating with a molding cavity, the walls presenting a stepped neck which is dimensionally accurate within .+-.0.002 inches, the mold further including a metal support associated with the core element. The insert assembly comprises: (a) a metal guide detachably secured to the metal support; (b) a metal chill element extendible through the opening to present a metal molding surface which insert has walls mateable with the stepped neck for accurate alignment; and (c) biasing means acting between the guide and insert to urge the mating walls together for self positioning of the insert. The insert assembly can be repeatedly reused in a method of making castings.

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 mold within which molten metal is sand cast, is provided with strategically located chill plates which shape and rapidly cool the molten metal at predetermined locations for hardening those locations relative to the hardness of the remainder of the casting. The mold is formed of a cope and drag frame type flask within which sand is compacted to form the sand cavity. Plates are arranged transversely of the casting cavity and are secured to portions of the flask frame for dissipating heat through the plates and out through the frame. The plates are fixed to portions of the flask and are arranged in opposing pairs which are aligned, coplanar, in abutting relationship. Each plate of each pair is provided with a notch, aligned with its opposite plate, for encircling the portion of the casting to be chill hardened. The pattern used for forming the cavity extends through the aligned notches and between the plates to form the composite sand and metal plate casting surface in the cavity.

Abstract: A static casting method for a hollow cast product using a mold with bottom comprising a top lid, a core and an outer mold section, the core being attached to the top lid and disposed inside the outer mold section. The outer mold section includes a lateral mold section and a lower mold section. The lateral mold section is formed at its inner peripheral wall portion with a composite cooling section by stacking chiller blocks and interposing therebetween refractory sands and at its outer wall portion with refractory sands. Cooling pipes include first and second pipes. A first pipe extends longitudinally through the refractory sands at the outer wall portion and a second pipe extends longitudinally through the inner wall portion in contact with at least a part of each of the chiller blocks, the first and second pipes being connected at their lower portions through the bend portion. The chiller blocks are cooled by water flowing in the second pipes. The entire casting cavity is first filled with molten metal.

Abstract: A static casting mold for hollow cast product with bottom comprising a top lid, a core and an outer mold section, the core being attached to the top lid and disposed inside the outer mold section. The outer mold section includes a lateral mold section and a lower mold section. The lateral mold section is formed at its inner peripheral wall portion with a composite cooling section by stacking chiller blocks and interposing therebetween refractory sands and at its outer wall portion with refractory sands. Cooling pipes includes a first and second pipes. A first pipe extends longitudinally through the refractory sands at the outer wall portion and a second pipe extends longitudinally through the inner wall portion in contact with at least a part of each of the chiller blocks, the first and second pipes being connected at their lower portions through the bend portion. The chiller blocks are cooled by water flowing in the second pipes.