Abstract: In various aspects, a preheater, a directed flow chemical vapor infiltration/chemical vapor deposition (CVI/CVD) furnace, and/or an installation jig are described. In one example, a preheater includes a central inlet; a circuitous gas flow path downstream of the central inlet; a plenum section downstream of the circuitous gas flow path; and an outlet diffuser plate defining a plurality of apertures fluidly configured to couple the preheater to a furnace working zone, wherein the outlet diffuser plate is downstream of the plenum section, wherein the circuitous gas flow path is fluidly coupled to the plenum section by an outer circumferential slot opening.

Abstract: Additive manufacturing structures and methods that enable the facile release of 3D printed parts are described. In one implementation, an additive manufacturing structure includes: a body; and a recessed section formed through a surface of the body, the recessed section comprising: a pour hole for filling the recessed section with a liquid metal or metal alloy that solidifies into an insert having a surface for forming a 3D object in a 3D printing device; and one or more air holes configured to release air displaced by the liquid metal or metal alloy.

Abstract: Provided is a system for casting molten metals. The system includes a mould comprising a casting cavity having an inlet, and a bore between an upper surface of the mould and the inlet. The system further includes a shroud comprising a funnel and a hollow shaft, wherein the funnel is located outside of the mould, adjacent the upper surface, and the hollow shaft is received within the bore and is moveable therein. A lifting mechanism is located on the upper surface of the mould, the lifting mechanism being operable to lift the funnel of the shroud away from the upper surface for bringing the shroud into engagement with a ladle nozzle. Also provided is a method for casting molten metals using the system.

Abstract: A method of transferring molten metal to a die casting mold is disclosed. The method includes providing a ladle with a dip well and a dispensing nozzle having a fluid metal filter formed therein as well as providing a receptacle fluidly between the ladle and the mold. Further the method includes delivering the molten metal from the ladle to the receptacle by positioning an exit face of the dispensing nozzle over the receptacle and rotating the ladle such that the exit face of the dispensing nozzle is repositioned proximal the bottom of the receptacle and conveying the molten metal that has been delivered to the receptacle into a mold cavity that is placed in fluid communication therewith.

Abstract: Method and apparatus for flowing molten metal substantially vertically into a mold by means of a feeder tube while concurrently impeding the flow of oxides that collect at the perimeter of the head of the feeder tube. This reduces inclusions in the molten metal and improves the quality of a molded component as the molten metal solidifies.

Abstract: One embodiment of the present invention is a unique filter and a method for manufacturing the same. Another embodiment is a unique system for casting a metallic object. Another embodiment is a unique method of filtering a molten metal. Other embodiments include apparatuses, systems, devices, hardware, methods, and combinations for filtering molten metal. Further embodiments, forms, features, aspects, benefits, and advantages of the present application shall become apparent from the description and figures provided herewith.

Abstract: Of the many embodiments provided, one embodiment is a drill bit mold assembly comprising: a mold having a bottom and at least one side; a core centrally disposed within the mold; and a filter disposed above the bottom of the mold and within a space formed between the at least one side of the mold and the core.

Abstract: A mold for casting metal which allows solid impurities to be removed from the molten metal. The mold (50) has a cavity therein, said cavity having a casting portion and contiguous therewith a running system upstream of the casting portion, said running system comprising an upstream inlet portion (58), a downstream outlet portion (60) and a swirl chamber (54) disposed between the inlet and outlet portions (58, 60), wherein a filter (62) is provided at an interface between the swirl chamber (54) and the outlet portion (60). The application also relates to a method for preparing the mold, a pattern for preparing the mold, a housing for use in the mold and a method for casting employing the mold.

Abstract: Four cavities are arranged on a concentric circle “C” with respect to the center “O” of a flow divider and a gate sleeve. Each of the cavities is connected to a sleeve stamp portion through each of four die side runners and each of four stamp side runners formed in a radial direction and separated from the neighboring runners. A semicircular arc-shaped reservoir is provided between the lower half side of the flow divider and the lower half side of the gate sleeve. This reservoir is connected to the sleeve stamp portion. A semi-solidified layer formed by pouring the molten metal into a sleeve is filled into the reservoir, so that the molten metal from which the semi-solidified layer is separated can be filled directly from each of the stamp side runners via the die side runners into each of the cavities evenly and simultaneously.

Abstract: A mould for casting metal which allows solid impurities to be removed from the molten metal. The mould (50) has a cavity therein, said cavity having a casting portion and contiguous therewith a running system upstream of the casting portion, said running system comprising an upstream inlet portion (58), a downstream outlet portion (60) and a swirl chamber (54) disposed between the inlet and outlet portions (58,60), wherein a filter (62) is provided at an interface between the swirl chamber (54) and the outlet portion (60). The application also relates to a method for preparing the mould, a pattern for preparing the mould, a housing for use in the mould and a method for casting employing the mould.

Abstract: A method of casting a base of high-power wind turbines with low-temperature nodular graphite iron, using furan resin sand as the mold sand and having no risers or chills in the mold. The mold undergoes microseismic compaction and has no chills risers. The parting face of the mold is perpendicular to the ground. The molten iron in the mold is solidified evenly. Therefore, shrinkage holes and disperse shrinkages base are reduced greatly and the dregs and air are discharged easily for the base. The pouring system designed together with a reasonable pouring rate and time make the filtering system useful for blocking dregs.

Abstract: This invention relates to filters made from a refractory material, preferably an insulating material, and chemical binder. The filters are used in the foundry industry to filter molten metal. The invention also relates to a process for preparing the filters.

Abstract: Methods for reducing inclusion content of sputter targets and targets so produced are disclosed. Inclusions may be reduced by adding a small amount of Si to the molten Al or molten Al alloy followed by filtering of the molten metals through a filter medium. Targets having substantially no inclusions therein of greater than about 400 ?m are especially useful in the sputtering of large flat panel displays and result, upon sputtering, in a reduction in the amount of macroparticles sputtered onto the substrate.

Abstract: A technique for pressurized or differential pressure casting according to the present disclosure provides a riser tube filter formed of ceramic foam having a specific gravity lower than the molten metal to be cast. A riser tube filter according to the present invention may float in and/or on the molten metal within the riser tube and smooth the flow of molten metal within the riser tube simultaneously filtering the metal. As the molten metal is depressurized, a riser tube filter according to the present disclosure will travel back down the riser tube engaging the walls of the riser tube and minimizing the surface of molten metal in contact with the air or other gas. It is emphasized that this abstract is provided to comply with the rules requiring an abstract that will allow a searcher or other reader to quickly ascertain the subject matter of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims.

Abstract: A dispensing arrangement for inserting a part into a cast iron mold includes a dispenser apparatus configured to dispense a predetermined number of parts, a staging apparatus configured to position the parts in a selective orientation and a jig apparatus configured to grip and lift the parts from the staging apparatus and position the parts in a die of a mold. The apparatus may be located adjacent the mold in use.

Abstract: A filter material for molten aluminum, the material subsequently dissolvable in molten aluminum to recover aluminum captured therein.

Abstract: Intervening fingers mounted within a mold gate cavity extend across a portion of the gate cavity and cooperate with one another to slow the flow of molten metal into the mold cavity and thereby reduce flow turbulence.

Abstract: An apparatus for casting an ingot includes a molten metal reservoir (51) positioned at an upper portion, a casting chamber (5) positioned at a lower portion and a partition wall (3) between the reservoir and the chamber, a spruce (7) formed in the partition wall, an opening/closing plug (8) for opening and closing the sprue and control means for controlling an opening and closing operation of the plug. The casing chamber is defined in a mold (1) that includes a lower mold member (4), a side mold member (2) and the partition wall (3) that constitutes an upper mold member. At least one of the lower mold member, side mold member and upper mold member includes a plurality of divided sections (21,22) in accordance with a shape of a cast ingot C.

Abstract: A dispensing arrangement for inserting a part into a cast iron mold includes a dispenser apparatus configured to dispense a predetermined number of parts, a staging apparatus configured to position the parts in a selective orientation and a jig apparatus configured to grip and lift the parts from the staging apparatus and position the parts in a die of a mold. The apparatus may be located adjacent the mold in use.

Abstract: An apparatus and method for casting metallic components is disclosed. The apparatus has a vertical parting line and a gate configuration which reduces defects within the cast components.

Abstract: The present invention of a gating system comprises the use of modular gating system consisting of one or more filtering media flanked on at least one side by an evaporative foam layer, which is left inside the mold. The modular gating system permits the entry of metal to any surface of the mold without going through the parting line of the pattern.

Abstract: A modular casting system includes a plurality of casting modules and, is provided with on-board systems such as a lubrication system, cooling system, etc., which operate independently from similar systems on other modules of the system. Each of the casting modules is connected by quick disconnect connections to a centrally disposed source of fluid pressure and electrical power and a control unit for controlling each of the modules independently. Each of the modules is readily removable from the system and replaced with a new module of a different type or with a different mold. Each of the modules is preferably provided with a filter removal unit which is operative to raise the filter during the cooling operation and facilitates removal of the filter upon completion of the pouring operation. The upper platen of a casting module is provided with a swinging cope which is movable between a horizontal position and a vertical position to facilitate cleaning of the cope.

Abstract: An apparatus for separating casting strainers and transferring each separated casting strainer to a predetermined position. The apparatus includes a casting strainer receiving member in which a plurality of casting strainers are stacked up, a slide member for horizontally sliding under the casting strainer receiving member, a separator projecting from the slide member towards the casting strainers, a casting strainer stopper formed at the lower end or vicinity of the casting strainer receiving member, a casting strainer passage formed in the slide member at an area immediately under a projecting end of the separator for receiving the separated casting strainer, and a shooter formed under the slide member for transferring the casting strainer to the predetermined position.

Abstract: A filter assembly for filtering molten metal poured into a mold includes a filter formed from refractory material, the filter having first and second porous surfaces through which molten metal may flow, and a peripheral surface and a locator attachable to at least one of the first, second and peripheral surfaces of the filter and arranged to extend from the at least one of the first, second and peripheral surfaces of the filter to another of the first, second and peripheral surfaces or to another part of those surface(s), during use. The locator locates the filter in a mold into which molten metal is poured.

Abstract: A method of ascending casting in a casting cavity where filling from the bottom results in a region of reduced pressure formed during the cooling in which solidification can be expected to take place last. The region is post-fed with molten material from a shortest possible feeding duct. By doing this, the consumption of casting metal is reduced, because it is no longer necessary to use a surplus of molten material to keep the bottom ingate open for feeding purposes and the consumption of mold material is also reduced because it is no longer necessary to adapt the mold to accommodate surplus molten material.

Abstract: The ratio of the number of free holes (4a) in a filtering plate (2, 3), located in the areas (9) which are not covered by the an insert (7) of treating material, on the one hand, to the total number of holes (4, 4a) in said filtering plate (2, 3), on the other hand, is not less than 10% and/or not above 75%.

Abstract: In an arrangement of an ingate system with feeding reservoir for feeding castings, preferably in moulds with pouring form the bottom (ascending casting), with which ingate system at least a feeding reservoir is connected. The ingate system is connected to one or a number of mould cavities least one feeding reservoir (7) is provided consituting a widened part of a duct (4) or a part of a duct in the ingate system (1), and that a partition (6) consisting of a gauze screen (6) or equivalent is provided separating the feeding reservoir (7) and the duct (4).

Abstract: A mold for gravity casting vehicle wheels having reusable thermally insulative linings attached to the interior of the gate and ball riser cavities. After filling the mold with molten metal, the gate cavity can be pressurized to assure that the mold cavity is completely filled. The ball riser cavity also can be pressurized subsequent to the gate cavity pressurization. The pressure on the gate and ball riser cavities forces molten metal from the cavities into the mold cavity as the metal cools and solidifies.

Abstract: A portable sand mold metal treating system having sand cope and sand drag portions, the treating system being attachable to a sand mold metal casting system.

Abstract: A filter for molten metal comprises a series of at least two refractory mineral material plates which define between them one or more cavities. The plates each comprise a series of holes through which the liquid metal passes and by which the liquid metal is filtered. At least one of the cavities contains a material for treating the metal, for example a material for inoculating the liquid metal. The filter is used among other things to filter and treat molten metals simultaneously and to improve the quality of the metal.

Abstract: An apparatus and method for filtering molten metal are disclosed. The apparatus utilizes a continuous filtering medium that is serially indexed into the metal filtering area. The apparatus may be used to filter ferrous and non-ferrous metals, and provides significant cost and time savings. In one embodiment the apparatus allows automatic indexing of a new filter for each shot or pour on high production casting machines. In another embodiment the apparatus is adapted to filter large amounts of metal up to 5,000 pounds or more.

Abstract: A technique and accompanying apparatus to promote increased yield, improved surface finish and microstructure, and faster cycling time for precision-sand casting process. Aluminum products are cast by: (a) forming a precision sand mold, devoid of risers and/or vents, and a gating system consisting of a gravity feeding sprue and one or more runners effective to carry molten metal from the sprue only to the bottom of the mold cavity; (b) planting a flow modifier in the gating system between the sprue and mold effective to convert the flow into laminar quiescent flow; and (c) filling the gating system with molten aluminum metal at a rate faster than 4 pounds/second as permitted by the laminar flow that more rapidly fills the mold and acts as a heat sink to prevent a drop in temperature of the in-coming molten metal and thereby increase yield as well as minimizing cycle time.

Abstract: A filter for molten metal comprises a series of at least two refractory mineral material plates which define between them one or more cavities. The plates each comprise a series of holes through which the liquid metal passes and by which the liquid metal is filtered. At least one of the cavities contains a material for treating the metal, for example a material for inoculating the liquid metal. The filter is used among other things to filter and treat molten metals simultaneously and to improve the quality of the metal.

Abstract: An apparatus and method for filtering molten metal are disclosed. The apparatus utilizes a continuous filtering medium that is serially indexed into the metal filtering area. The apparatus may be used to filter ferrous and non-ferrous metals, and provides significant cost and time savings. In one embodiment the apparatus allows automatic indexing of a new filter for each shot or pour on high production casting machines. In another embodiment the apparatus is adapted to filter large amounts of metal up to 5,000 pounds or more.

Abstract: A casting mold assembly includes cope and drag sections having a casting cavity therebetween and a casting core supported within the cavity. A vertical down sprue extends through the cope section and joins a flow passage extending through the core in prolongation of the down sprue for introducing molten metal directly into the mold cavity to produce a disk brake rotor. A filter is supported in the flow path of the core and a flow control lip is provided at the exit of the flow path to provide a flow constricting gap between the annular lip and an underlying lower cavity wall to slow the flow of metal into the cavity.

Abstract: The sprue/riser sleeve 40 has a tubular, preferably cylindrical wall 42 extending between an inlet end 48 and an outlet end 50. The sleeve 40 has a woven mesh filter extending across a central passageway 51 with a periphery 54 of the filter 52 embedded into the wall 42. The periphery 54 has three or more, evenly spaced tabs 56 formed thereon that project further into or through the wall to secure the filter to the wall without materially weakening the wall. Preferably, the filter has a square-shaped periphery 54 with corners 64 that define the tabs 56. The main portion of the periphery extends into the wall less that one-half the thickness of the wall, whereas the tabs extend into the wall a distance greater than one-half the thickness.

Abstract: An improved mold for use in casting a metal airfoil has an airfoil mold cavity and a starter chamber. A lower end of the starter chamber is formed by a chill plate. A filter is disposed in the starter chamber between the airfoil mold cavity and the chill plate. When an airfoil is to be cast, molten metal is conducted into the starter chamber, into passages in the filter and into the airfoil mold cavity. The molten metal is solidified upward in the starter chamber from the chill plate and through the passages in the filter. The filter blocks migration of impurities from the starter chamber to the airfoil mold cavity as the metal solidifies in the starter chamber. As the molten metal begins to solidify in the airfoil mold cavity, the molten metal is solidified as a large number of columnar grain crystals which extend from the passages in the filter into the airfoil mold cavity.

Abstract: Metallurgically treated metal castings are produced using a consumable plug assembly made of a meltable material which is placed in a reaction chamber in an open treating basin and above a passage to a molding cavity. The consumable plug assembly has physical and chemical characteristics which maintain the plugged relationship for a preselected retaining period. All of a treating material is placed on the plug in the reaction chamber prior to metal pouring so as to react directly with the poured metal in a non-dynamic way.

Abstract: A ceramic shell mould (70) for casting a single crystal turbine blade comprises a plurality of article portions, (72), each of which has an article chamber (74) for defining the shape of a turbine blade, a plurality of selector portions (76), a plurality of starter portions (80) and a runner portion (84). The runner portion (84) comprises a first subsection (86) which has a central axis (87) arranged parallel to, and spaced from, the central axes (73) of the article portions (72) and a plurality of second subsections (90) which interconnect the first subsection (86) with the article portions (72). The second subsections (90) are arranged to make an acute angle with the first subsection (86) of the runner portion (84) and with the starter portions (80) so that the second subsections (90) may bend to allow relative movement between the first subsection (86) and the starter portions (80) to prevent the cast turbine blades falling off the mould.

Abstract: A molten metal filter is disclosed having a carbon or carbon-thermite coating that reduces thermal shock to the filter, and protects the filter from corrosion from the metal or components and impurities in the metal, and prevents metal from freezing in the filter. A molten metal assembly suitable for casting molten metal is disclosed which comprises a filter for molten metal and means for molten metal flow passage leading through the filter. The means have surfaces defining a molten metal path. The filter has a coating of carbon or carbon in intimate contact with a thermite material on the surface of the filter. A process is disclosed for filtering molten metal which comprises passing molten metal through the above described coated filter.

Abstract: Molten iron is cast into a mould through a filter located in the runner system of the mould using a filter comprising a body having a plurality of cells, at least some of the cells having their walls at least partially coated with a first layer of wax and a second layer of an inoculant, such as graphite, calcium silicide or ferrosilicon, for the iron.

Abstract: A mould (61) for metal casting has a mould cavity (62) and a sprue (63) communicating directly with the mould cavity (62) and located in the sprue (63) a sleeve (64) of refractory material having a cellular ceramic filter (65) fixed therein. The mould, which has no running system apart from the sprue, may be a sand mould or a metal die for producing castings by gravity or low pressure diecasting. The cellular ceramic filter may be a honeycomb type of structure having cells which extend between two outer surfaces of the filter or a structure having interconnecting cells such as a ceramic foam.

Abstract: A filter for molten metal with a particulate coating for simultaneously metallurgically treating and filtering is disclosed. A layer of particulates such as ferroalloy, deoxidizer, grain refiner, inoculant or master alloy is placed on the surface of a hard-fired ceramic or refractory cloth filter for treating liquid metal. The particles are held in place by a coating of carbonaceous resin which is applied to the surface of the filter and which also protects the filter and particles against abrasion and moisture. The placement of the particulate additives on the filter allows the molten metal to be metallurgically treated and filtered simultaneously.

Abstract: A mould (61) for metal casting has a mould cavity (62) and a sprue (63) communicating directly with the mould cavity (62) and located in the sprue (63) a sleeve (64) of refractory material having a cellular ceramic filter (65) fixed therein. The mould, which has no running system apart from the sprue, may be a sand mould or a metal die for producing castings by gravity or low pressure diecasting. The cellular ceramic filter may be a honeycomb type of structure having cells which extend between two outer surfaces of the filter or a structure having interconnecting cells such as a ceramic foam.

Abstract: A mould for the production of a nodular or compacted graphite iron casting has parts comprising a treatment sprue, a runner, a slag trap, a filter chamber having an ingate and an outlet and having located therein a ceramic filter having an inlet and outlet, a casting cavity ingate, and a casting cavity, and the parts of the mould have a relationship one with another such that F2=0.8 F1 to 1.2 F1, F3=30% F4 - 100% F4, F4.gtoreq.4.5 F1, F5.gtoreq.1.3 F1, F6=2 F5 to 4 F5, F7.gtoreq.F5 and .ltoreq.F6, F8.gtoreq.F5 and .ltoreq.F6, F9=1.2 F1 to 3 F1, F10.gtoreq.

Abstract: A casting mold having first and second casting mold halves is provided with a sprue system in the first casting mold half which comprises a sprue casting mold half which comprises a sprue cup for receiving molten metal and feeding same to a feeder provided with a filter which filters the molten metal prior to delivering same to a mold cavity provided in the second casting mold half.

Abstract: A gravity poured foundry mold having a gating system and at least one complete mold casting cavity, the gating system allowing castings to be made in more compact molds, using less metal at lower temperature, obtaining less solidification strained castings, and requiring less fettling work and less pattern work. The gating system combines the use of a strainer such as a skin-strainer with any of several fluid restraining devices including but not limited to skin-strainer covers, restraining floating pieces, non-floating restraining pieces and blind floating pieces. Also disclosed are applications in which a skin-strainer is omitted. There is disclosed apparatus which may be standardized, thereby greatly increasing the ease, accuracy and confidence with which the gating system may be used in foundries which would have available to them sets of different sizes of standardized, interchangeable and prefabricated elements as disclosed herein.

Abstract: Apparatus for the vacuum-assisted, countergravity casting of thin-walled metal parts includes a plurality of expendable casting molds supported on a top side of a reusable drag slab. Each casting mold includes a mold cavity and a mold ingate passage extending from the mold cavity into registry with a respective underlying slab ingate passage that extends between the top side and a bottom side of the drag slab and that optionally includes a molten metal filter therein. When the bottom side of the drag slab is immersed in an underlying molten metal pool with the mold cavities evacuated, the molten metal is drawn upwardly through each slab ingate passage and the molten metal filter therein and then through each mold ingate passage registered therewith into each mold cavity. The molten metal filter in each slab ingate passage removes inclusion-forming impurities from the molten metal as it is drawn upwardly into each mold cavity.

Abstract: Apparatus for casting molten metal including a mold for casting molten metal having a base portion, a molten metal inlet located at the base portion, a filter positioned across the molten metal inlet so that all the molten metal must pass therethrough and a well beneath said inlet and beneath said filter.

Abstract: A filter for molten metal having a high melting point is in the form of a net woven of glass yarns formed by twisting a multiplicity of glass fibers together. The glass fibers contain at least 75 wt. % of SiO.sub.2 and are thermally cured at a thermal shrinkage of 2.5 to 15%. The thermal shrinkage is expressed by (l-l')/.times.100 % wherein l is the length of the fiber before the thermal cure, and l' is the length of the fiber as thermally cured.