Including Means To Compensate For Shrinkage (e.g., Shrink Head, Etc.) Patents (Class 164/359)
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Patent number: 11964873Abstract: A method is presented for producing hollow microspheres of metal oxides (HMOMS) and/or hollow metal silicates microspheres (HMSMS) in a transforming solution. The transforming solution contains an atom M, or an M-ion, or a radical containing M. M in the transforming solution has the thermodynamic ability to replace silicon atoms in hollow silica microspheres (HSMS) and/or hollow glass microspheres (HGMS). The maximum temperature for transformation is set by the chemical physical properties of the transforming solution, and the viscosity of the silica in the walls of the HSMS and/or the glass in the walls of the HGMS. Viscosity, of enough magnitude, helps retain the desired shape of the hollow sphere as it is transformed to HMOMS and/or HMSMS. Non-spherical shapes can be produced by increasing the transformation temperature whereby the viscosity of the walls of the HSMS and/or the HGMS is reduced.Type: GrantFiled: August 25, 2020Date of Patent: April 23, 2024Assignee: Plassein Technologies Ltd LLCInventor: David Charles Lynch
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Patent number: 11801550Abstract: The present invention relates to a feeder system for use in metal casting operations utilising casting moulds and to a feeder sleeve for use in the feeder system. There is provided a feeder system for metal casting, the feeder system comprising a feeder sleeve mounted on a breaker core, the feeder sleeve having a first end and an opposite second end, a longitudinal axis extending between the first and second ends, and a continuous sidewall extending generally around the longitudinal axis between the first and second ends, the sidewall defining a cavity for receiving molten metal during casting, and the breaker core defining an open bore therethrough for connecting the cavity to the casting, wherein the first end of the feeder sleeve is mounted on the breaker core, and the feeder sleeve comprises at least one protrusion extending from an exterior surface of the sidewall at the second end of the feeder sleeve.Type: GrantFiled: March 26, 2021Date of Patent: October 31, 2023Assignee: FOSECO INTERNATIONAL LIMITEDInventor: Anton Viktorovich Soloveykin
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Patent number: 11173541Abstract: The invention relates to a method for producing a mold part (26, 26?) with a feeder insert arranged in it, with a sprue for liquid metal, for a divisible casting mold for metal casting, with the following steps: producing or providing a mold part (26, 26?) equipped with a closed feeder insert (2, 2?) from a compacted molding material (28), the closed feeder insert (2, 2?) being arranged fixed in place in the compacted molding material (28) of the mold part (26, 26?) and having a feeder opening (10, 10?) connected to regions of the mold cavity (30, 30?) that is to be formed, and opening the closed feeder insert (2, 2?), so that a sprue (32, 32?) for liquid metal is formed.Type: GrantFiled: November 19, 2018Date of Patent: November 16, 2021Assignee: CHEMEX FOUNDRY SOLUTIONS GMBHInventors: Michael Biemel, Heiko Schirmer
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Patent number: 10286445Abstract: A feeder system for metal casting comprising a feeder sleeve mounted on a tubular body. The feeder sleeve has a first end and a second end and a longitudinal axis extending generally between said first and second ends. The feeder sleeve comprises a continuous sidewall that extends generally around the longitudinal axis that defines a cavity for receiving liquid metal during casting and the sidewall has a base at the first end of the feeder sleeve. The tubular body defines an open bore therethrough for connecting the cavity to the casting in use. The feeder sleeve comprises at least one cut-out that extends into the sidewall from the base to a first depth and the tubular body projects into the cut-out to a second depth, the tubular body having at least one abrading region in contact with a surface of the feeder sleeve within the cut-out.Type: GrantFiled: September 2, 2015Date of Patent: May 14, 2019Assignee: FOSECO INTERNATIONAL LIMITEDInventor: Christof Volks
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Patent number: 10022783Abstract: A feeder system for metal casting comprising a feeder sleeve mounted on a tubular body. The tubular body has a first end and an opposite second end and a compressible portion therebetween so that upon application of a force in use, the distance between the first and second ends is reduced. The feeder sleeve has a longitudinal axis and comprises a continuous sidewall extending generally around the longitudinal axis that defines a cavity for receiving liquid metal during casting, the sidewall having a base adjacent the second end of the tubular body. The tubular body defines an open bore therethrough for connecting the cavity to the casting. The feeder sleeve has at least one cut-out that extends into the sidewall from the base and the second end of the tubular body projects into the cut-out to a fixed depth. The cut-out can be a groove which is separate from the cavity. The invention also resides in a feeder sleeve for use in the system and a process employing the feeder system.Type: GrantFiled: September 2, 2015Date of Patent: July 17, 2018Assignee: FOSECO INTERNATIONAL LIMITEDInventors: Christof Volks, Harun Öztürk
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Patent number: 9987676Abstract: A feeder insert for use for the casting of metals into casting molds, having a mold body (6) and a supply element (4) which delimit the feeder cavity (10) for receiving liquid metal, wherein the supply element (4) has a passage opening (26) for the liquid metal, and wherein the mold body (6) is movable in a feeder longitudinal direction relative to at least one part of the supply element (4), characterized in that the supply element (4) has a deformation region which is designed to trim in at least in sections in at least a first phase of a relative movement of the mold body (6) in the feeder longitudinal direction and in the direction of the supply element (4).Type: GrantFiled: January 10, 2014Date of Patent: June 5, 2018Assignee: CHEMEX GMBHInventors: Lars Zumbusch, Guido Brieger, Michael Biemel
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Patent number: 9968993Abstract: The present invention relates to a feeder system for metal casting. The feeder system comprises a feeder sleeve mounted on a tubular body. The feeder sleeve has a longitudinal axis and comprises a continuous sidewall that defines a cavity for receiving liquid metal during casting. The sidewall extends generally around the longitudinal axis and has a base adjacent the tubular body. The tubular body defines an open bore therethrough for connecting the cavity to the casting. A groove extends into the sidewall from the base to a first depth and the tubular body projects into the groove to a second depth and is held in position by retaining means. The second depth being less than the first depth so that upon application of a force in use the retaining means are overcome and the tubular body is pushed further into the groove.Type: GrantFiled: September 2, 2015Date of Patent: May 15, 2018Assignee: FOSECO INTERNATIONAL LIMITEDInventor: Christof Volks
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Patent number: 9890439Abstract: A method for casting cast parts in which a casting mould is provided. The casting mould is enclosed in a housing, forming a filling space between an inner surface section of the housing and an associated outer surface section of the casting mould. The filling space is then filled with a free-flowing filling material and molten metal is poured in the casting mould. As a consequence a binder of the mould material begins to vaporise and combust disintegrating the casting mould. During the filling of the filling space, the filling material has a minimum temperature, starting out from which the temperature of the filling material rises, to beyond a boundary temperature at which the vaporising binder ignites and combusts.Type: GrantFiled: July 20, 2015Date of Patent: February 13, 2018Assignee: Fritz Winter Eisengiesserei GmbH & Co. KGInventors: Klaus Arnold, Dirk Rogowski, Jürgen Schmidt, Rolf Süssmann
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Patent number: 9114452Abstract: A metal casting riser sleeve system includes a cope mold portion and an outer riser sleeve portion positioned in the cope mold portion. The outer riser sleeve portion encloses a central outer riser sleeve portion passageway between an outer riser sleeve portion bottom end and top end. The system also includes an inner riser sleeve portion that forms a central inner riser sleeve portion passageway between an inner riser sleeve portion bottom end and top end. The inner riser sleeve portion is slidably positioned within the outer riser sleeve portion passageway. The inner riser sleeve portion is operable to slide upward such that the inner riser sleeve portion top end is above the outer riser sleeve portion top end and such that a riser sleeve system passageway is formed between the inner riser sleeve portion top end and the outer riser sleeve portion bottom end.Type: GrantFiled: October 21, 2013Date of Patent: August 25, 2015Assignee: McConway & Torley, LLCInventor: Ohannes G. Mangoyan
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Patent number: 9114454Abstract: An arrangement and method in a ram-up machine (1) for moulds (2) for metal casting (10) comprising:—a squeeze plate (3) carrying a first mould pattern (32)—a horizontally movable piston (31) for operating the squeeze plate (3) and a finished mould block (2),—a sand supply system (7)—a swing plate (4) carrying a second mould pattern (42), the swing plate (4) is configured to be translatorily movable in a horizontal direction to a released position (4r) and further to be pivotable upwardly to a sidestep position (4s),—a feeder element insertion configuration (50) wherein one or plurality of feeder elements (5) are configured to be attached to the second mould pattern (42) when during operation the swing plate (4) carrying the second mould pattern (42) is pivoted to the sidestep position (4s).Type: GrantFiled: June 13, 2011Date of Patent: August 25, 2015Assignee: COMPONENTA OYJInventors: Seppo Paalanen, Arto Rautakoski
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Patent number: 9027801Abstract: An elongate collapsible feeder element for use in metal casting and a feeder system with attached feeder element and feeder sleeve. The feeder element has an A end and an opposite B end measured along the height, and a C end and an opposite D end measured along the length. The A end is for mounting on a mold pattern or swing plate and the opposite B end is for receiving a feeder sleeve. A bore is between the A and B ends defined by a sidewall having a stepped collapsible portion. The feeder element is compressible in use to reduce the distance between the A and B ends. The bore is offset from the centre of the feeder element along the length towards the C end and a second sidewall region is non-planar, contiguous with a third sidewall region and located between the bore axis and the D end.Type: GrantFiled: December 5, 2012Date of Patent: May 12, 2015Assignee: Foseco International LimitedInventors: Jan Sällström, Paul David Jeffs
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Patent number: 9027631Abstract: Metal alloy injection molding techniques are described. In one or more implementations, these techniques may also include adjustment of injection pressure, configuration of runners, and/or use of vacuum pressure, and so on to encourage flow of the metal alloy through a mold. Techniques are also described that utilize protrusions to counteract thermal expansion and subsequent contraction of the metal alloy upon cooling. Further, techniques are described in which a radius of edges of a feature is configured to encourage flow and reduce voids. A variety of other techniques are also described herein.Type: GrantFiled: December 14, 2012Date of Patent: May 12, 2015Assignee: Microsoft Technology Licensing, LLCInventors: Paul C. Bornemann, Raj N. Master, Michael Joseph Lane, Seah Sun Too
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Patent number: 8991473Abstract: Metal alloy injection molding techniques are described. In one or more implementations, these techniques may also include adjustment of injection pressure, configuration of runners, and/or use of vacuum pressure, and so on to encourage flow of the metal alloy through a mold. Techniques are also described that utilize protrusions to counteract thermal expansion and subsequent contraction of the metal alloy upon cooling. Further, techniques are described in which a radius of edges of a feature is configured to encourage flow and reduce voids. A variety of other techniques are also described herein.Type: GrantFiled: February 10, 2014Date of Patent: March 31, 2015Assignee: Microsoft Technology Holding, LLCInventors: Paul C. Bornemann, Raj N. Master, Michael Joseph Lane, Seah Sun Too
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Patent number: 8844606Abstract: A method for machining a sand molding element, comprising: inserting at least one hollow center body having an internal cavity in a predetermined position in a casting flask; filling the internal cavity of the hollow center body with unbonded sand; filling the casting flask with bonded sand to obtain a sand block; machining a mold cavity in the sand block; and emptying the internal cavity from the unbounded sand. There is also provided a method for machining a molding core from a sand block, comprising: providing a core base member having a concave upper surface; forming a sand block on the core base member with a lower surface of the sand block resting on the concave upper surface; and machining the molding core into the sand block, the molding core having a convex lower surface complementary to the concave upper surface of the core base member.Type: GrantFiled: October 11, 2011Date of Patent: September 30, 2014Assignee: Nopatech Inc.Inventors: Philippe Dubuc, Marc Savard
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Patent number: 8770265Abstract: A casting apparatus for casting a railcar coupler, which includes a shank portion and a head portion, includes cope and drag portions that define an external shape of the coupler. The casting apparatus also includes one or more cores that define an interior of the shank portion and a separate head core with an exterior that defines an interior of the head portion that includes lock chamber, guard arm side portion, and knuckle side portions of the head. The head core is a single piece with a hollow center section that defines a front face gating system that includes at least one in-gate configured to direct molten material to top and bottom regions of the head to define the lock chamber, guard arm side portion, and knuckle side of the head.Type: GrantFiled: December 28, 2011Date of Patent: July 8, 2014Assignee: Bedloe Industries LLCInventors: F. Andrew Nibouar, Jerry R. Smerecky, Kelly S. Day, Nick Salamasick
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Patent number: 8733423Abstract: Metal alloy injection molding techniques are described. In one or more implementations, these techniques may also include adjustment of injection pressure, configuration of runners, and/or use of vacuum pressure, and so on to encourage flow of the metal alloy through a mold. Techniques are also described that utilize protrusions to counteract thermal expansion and subsequent contraction of the metal alloy upon cooling. Further, techniques are described in which a radius of edges of a feature is configured to encourage flow and reduce voids. A variety of other techniques are also described herein.Type: GrantFiled: December 14, 2012Date of Patent: May 27, 2014Assignee: Microsoft CorporationInventors: Paul C. Bornemann, Raj N. Master, Michael Joseph Lane, Seah Sun Too
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Patent number: 8430150Abstract: Feeder element for use in metal casting, having a first end for mounting on a mould pattern or swing plate, an opposite second end including a mounting plate for mounting on a feeder sleeve, and a bore between the first and second ends defined by a sidewall. The feeder element is compressible whereby to reduce the distance between the first and second ends. The bore has an axis that is offset from the centre of the mounting plate, and an integrally formed rim extends from a periphery of the mounting plate.Type: GrantFiled: December 2, 2011Date of Patent: April 30, 2013Assignee: Foseco International LimitedInventors: Jan Sallstrom, Paul David Jeffs
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Patent number: 8276644Abstract: A mold including a product cavity that is to be filled with a molten metal to mold a product; a supply cavity that connects to one side of the product cavity to supply the product cavity with the molten metal that is poured from a casting port; and a cooling cavity that connects to the other side of the product cavity and in which the molten metal filling the cooling cavity is cooled before the molten metal filling the product cavity and the supply cavity is cooled. A modulus M (=V/S) as a ratio of a volume V to a cooling surface area S in each of the cavities has a relation of Ms>Mp>Mc, where Mp is a modulus of the product cavity, Ms is a modulus of the supply cavity, and Mc is a modulus of the cooling cavity.Type: GrantFiled: November 15, 2011Date of Patent: October 2, 2012Assignee: Aisin Aw Co., Ltd.Inventor: Muneaki Akaneya
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Patent number: 8267151Abstract: A mold and method for gravity casting may integrally cast a turbine housing having a twin scroll unit and a bypass unit and an exhaust manifold having a plurality of exhaust runner units. A turbine housing-side riser may be formed based on the end portion of the twin scroll unit within a first mold and a second mold in the state where the cavity of the turbine housing is formed so that the end portion of the twin scroll unit which is the outlet of the turbine housing is upward disposed.Type: GrantFiled: September 21, 2011Date of Patent: September 18, 2012Assignees: Hyundai Motor Company, Kia Motors Corporation, Samshin Precision Co., Ltd.Inventors: Dong Ho Chu, Dong-chang Choi, Jae-yong Lee
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Publication number: 20120211192Abstract: The present invention relates to a feeder element for use in metal casting. The feeder element comprises a first end for mounting on a mould pattern or swing plate, an opposite second end comprising a mounting plate for mounting on a feeder sleeve and a bore between the first and second ends defined by a sidewall. The feeder element is compressible in use whereby to reduce the distance between the first and second ends. The bore has an axis that is offset from the centre of the mounting plate and an integrally formed rim extends from a periphery of said mounting plate. The feeder element of the invention finds particular utility in high pressure vertically parted sand moulding systems.Type: ApplicationFiled: December 2, 2011Publication date: August 23, 2012Applicant: Foseco International LimitedInventors: Jan Sallstrom, Paul David Jeffs
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Method of mitigating against thermal contraction induced cracking during casting of a super Ni alloy
Patent number: 8056608Abstract: A method of mitigating against thermal contraction induced cracking during casting of a super Ni alloy, the method comprising: pouring liquid alloy into a mould such that liquid alloy is present in a feeder of said mould; and inducing an electrical current in alloy in said feeder to reduce a rate of cooling of alloy in said feeder.Type: GrantFiled: April 24, 2009Date of Patent: November 15, 2011Assignee: Goodwin PLCInventors: Richard Stanley Goodwin, Stephen Roberts -
Patent number: 7934536Abstract: The invention relates to a feeder for cast metal, comprising a feeder head (1) having a cavity (5) that is open towards the surroundings via at least one opening (8), and a tubular body (2) which is guided through the opening (8) and arranged in a mobile manner. According to the invention, the tubular body (2) comprises an abutment (9) in the section thereof facing the cavity (5), said abutment (9) being capable of taking its bearing on a surface adjacent to the opening (8) in the cavity (5).Type: GrantFiled: February 20, 2006Date of Patent: May 3, 2011Assignee: AS Lungen GmbHInventor: Udo Skerdi
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Patent number: 7500509Abstract: The present invention relates to a feeder element (10) for use in metal casting. The feeder element (10) (which serves the function of a breaker core) has a first end (16) for mounting on a mould plate (24), an opposite second end (18) for receiving a feeder sleeve (20) and a bore (14) between the first and second ends (16,18) defined by a sidewall (12). The feeder element (10) is compressible in use whereby to reduce the distance between said first and second ends (16,18). The invention also relates to a breaker core/feeder sleeve assembly (10,20).Type: GrantFiled: October 21, 2004Date of Patent: March 10, 2009Assignee: Foseco International LimitedInventors: Colin Powell, Jan Sallstrom, Jan Eric Pehrsson
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Publication number: 20080230201Abstract: The invention relates to an insert to be inserted into a casting mold which is used for the casting of metals and has a casting cavity, having a body (3) which extends along a body longitudinal axis (7) and has a body cavity (6), the body (3) being constructed from at least one first shaped body (4), which has a connecting opening (10) by means of which the body cavity (6) can be connected to the casting cavity, and a second shaped body (5) which is placed onto the first shaped body (4), characterized in that the first shaped body (4) is embodied as an energy-absorbing device.Type: ApplicationFiled: March 31, 2005Publication date: September 25, 2008Inventor: Udo Skerdi
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Publication number: 20080223543Abstract: The invention relates to a feeder for cast metal, comprising a feeder head (1) having a cavity (5) that is open towards the surroundings via at least one opening (8), and a tubular body (2) which is guided through the opening (8) and arranged in a mobile manner. According to the invention, the tubular body (2) comprises an abutment (9) in the section thereof facing the cavity (5), said abutment (9) being capable of taking its bearing on a surface adjacent to the opening (8) in the cavity (5).Type: ApplicationFiled: February 20, 2006Publication date: September 18, 2008Applicant: AS LUNGEN GMBH & CO. KGInventor: Udo Skerdi
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Patent number: 7320355Abstract: This present invention concerns a feeder system for a cast piece with a feeder and/or feeder head and a tubular body, characterized in that the tubular body connects the feeder and/or feeder head directly or indirectly with the cast piece and/or the mold cavity and wherein the tubular body is made of cardboard or steel having a high carbon content.Type: GrantFiled: June 6, 2005Date of Patent: January 22, 2008Assignee: AS Lungen GmbH & Co. KGInventors: Udo Skerdi, Georg Scheerer
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Patent number: 7273085Abstract: Deoxidation casting machine, in which a deoxidizing compound reacts with a molten metal so as to deoxidize an oxide film formed on a surface of the molten metal. The machine includes a casting die having a molten metal inlet, a cavity into which a molten metal is poured from the molten metal inlet and a feeder head provided between the molten metal inlet and the cavity. A rate of cooling the molten metal in the feeder head is lower than that in the cavity.Type: GrantFiled: June 9, 2006Date of Patent: September 25, 2007Assignee: Nissin Kogyo Co., Ltd.Inventors: Keisuke Ban, Koichi Ogiwara
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Patent number: 7270172Abstract: This invention relates to an improved process for casting a metal by pouring molten metal into and around a casting assembly, where a riser containing a sleeve is a component of the casting assembly. The process comprises (a) inserting a riser insert into the cavity of the riser containing the sleeve, and (b) then allowing molten metal to flow into the cavity of the riser containing the riser insert. The density of the riser insert is such that the riser insert floats on the surface of the molten metal when the molten metal enters the cavity of the riser and provides a thermal barrier to reduce heat loss from the riser. The sleeve is shaped such that the riser insert will not be forced out or float off of the riser cavity when the metal is poured.Type: GrantFiled: November 3, 2005Date of Patent: September 18, 2007Assignee: Ashland Licensing and Intellectual Property LLCInventor: Ronald C. Aufderheide
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Patent number: 7270171Abstract: This invention consists of the use of an evaporative foam riser made with expanded polystyrene and with a cavity on top that contains an exothermic mixture. The reaction of the exothermic material, which is set off when it comes in contact with the metal, prolongs the solidification time of the riser thus rendering it more effective.Type: GrantFiled: May 26, 2004Date of Patent: September 18, 2007Inventors: Edgardo Campomanes, Patrick Campomanes
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Patent number: 7270168Abstract: The invention concerns a method for casting a part made of metal alloy such as an aluminum alloy comprising the following steps: forming a core (N, PNC) having at least one shaft (PC) designed to form in the part a cylinder and at least one cavity (P) designed to form in the part a support and/or retaining zone for a working member, and at least a cooling unit (RE) proximate to the cavity; positioning the core in a metal mould cavity, and feeding the mould lined with its liquid alloy core by gravity. The invention is particularly useful for casting internal engine cylinder blocks with aluminum cylinders with improved geometrical and mechanical properties of the crankshaft bearing zones.Type: GrantFiled: June 20, 2003Date of Patent: September 18, 2007Assignee: Montupet S.A.Inventors: Philippe Meyer, Franck Plumail
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Patent number: 7156146Abstract: A feeder insert is provided for a mold utilized for pouring metal. The insert includes a feeder body having a feed volume, in the form of an inner space, delimited by side walls and a top portion. A feed opening is provided in the base region for communicating with a hollow mold space. A domed feeder cap is displaceably disposed on a feeder body, surrounds the side walls of the feeder body to form an insulating gap, and is fixed in position relative to the feeder body prior to molding of the insert. At least one spacer of flexible material is disposed between the top portions of the feeder body and feeder cap such that during molding of the insert, and placement of the feeder body on the mold surface, due to molding pressure that occurs the feeder cap is displaceable relative to the feeder body while leaving an insulating gap between the top portions of the feeder body and feeder cap.Type: GrantFiled: November 19, 2002Date of Patent: January 2, 2007Assignee: GTP-Schafer Giesstechnishe Produkte GmbHInventors: Jürgen-Michael Schäfer, Thomas-Michael Schäfer
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Patent number: 7140415Abstract: A direct pour metal casting process and casting mold having a direct pour passage. The casting mold is filled from a bottom pour ladle that dispenses molten metal into a riser core. The riser core defines an opening that progresses from a circular opening in the top to a slot opening in the bottom of the riser core that is generally shaped as an inverted funnel.Type: GrantFiled: October 31, 2005Date of Patent: November 28, 2006Assignee: Ford Global Technologies, LLCInventors: Dennis Wilson, Venkat Nara
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Patent number: 7104309Abstract: In the method of deoxidation casting, a disused metal left in a feeder head can be easily removed from a cast product, or the molten metal left in the feeder head can be removed from the cast product so as to easily finish the cast product. The method comprises the steps of: pouring a molten metal into a cavity of a casting die; and reacting a deoxidizing compound with the molten metal so as to deoxidize an oxide film formed on a surface of the molten metal. And the method is characterized in that rate of cooling the molten metal in a feeder head of the casting die is lower than that in the cavity, and that the molten metal in the feeder head, which is not solidified, is treated when the molten metal in the cavity is solidified so as to make an outline of a cast product correspond to that of a desired product.Type: GrantFiled: September 2, 2003Date of Patent: September 12, 2006Assignee: Nissin Kogyo Co., Ltd.Inventors: Keisuke Ban, Koichi Ogiwara, Sakuzo Nakatani, Akira Sunohara
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Patent number: 6964293Abstract: The method of casting of the present invention is capable of making volume of a feeder head can be small and making cooling rate of the feeder head can be easily made lower than that of a cavity. The method is executed in a casting machine, which includes a casting die, in which the feeder head is provided between a metal inlet and the cavity and in which heat insulating of the feeder head is greater than that of the cavity so as to make cooling rate of the feeder head lower than that of the cavity. The method comprises the steps of: pouring a molten metal into the cavity; reacting the molten metal on a deoxidizing compound in the cavity so as to deoxidize an oxide film formed on a surface of the molten metal; and supplementing the molten metal in the feeder head to the cavity when the molten metal in the cavity is solidified and shrinked.Type: GrantFiled: June 2, 2004Date of Patent: November 15, 2005Assignee: Nissin Kogyo Co., Ltd.Inventors: Keisuke Ban, Akira Sunohara, Yasuhiro Sasaki, Koichi Ogiwara, Sakuzo Nakatani
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Patent number: 6948548Abstract: 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.Type: GrantFiled: August 31, 2001Date of Patent: September 27, 2005Assignee: Showa Denko K.K.Inventors: Shigeru Yanagimoto, Masashi Fukuda, Tomoo Uchida, Kunio Hirano
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Patent number: 6932144Abstract: A method of casting an object, usually a railroad wheel, is provided. A graphite mold having a drag section and a cope section requires a plurality of riser openings in the cope section to ensure proper dimensional accuracy of the cast railroad wheel by allowing molten metal to continue to feed downwardly through the riser openings to the cast wheel cavity during initial cooling. The riser openings are lined with an improved insulating material in an accurate manner such that the insulating material is added between a machined riser opening in the graphite cope mold section and a mandrel inserted in the riser opening.Type: GrantFiled: April 14, 2003Date of Patent: August 23, 2005Assignee: Amsted Industries Inc.Inventors: Mark S. Shirley, Michael A. Bland
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Patent number: 6904952Abstract: This present invention concerns a feeder system for a cast piece with a feeder and/or feeder head and a tubular body, characterized in that the tubular body connects the feeder and/or feeder head directly or indirectly with the cast piece and/or the mold cavity.Type: GrantFiled: November 2, 2001Date of Patent: June 14, 2005Assignee: AS Lungen GmbH & Co. KGInventors: Udo Skerdi, Georg Scheerer
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Patent number: 6848496Abstract: A casting apparatus for performing a casting while an oxide film formed on a surface of a molten metal is reduced by allowing the molten metal and a reducing compound to be contacted with each other, includes: a molding die having a cavity for receiving the molten metal, a sprue from which the molten metal is poured and a feeder head portion arranged between the sprue and the cavity. A difference of heat insulation is partially provided between the feeder head portion and the cavity such that the molten metal filled in the cavity and the feeder head portion is sequentially solidified in a direction of from a terminal portion of the cavity to the feeder head portion.Type: GrantFiled: December 4, 2003Date of Patent: February 1, 2005Assignee: Nissin Kogyo Co., Ltd.Inventors: Keisuke Ban, Akira Sunohara, Yasuhiro Sasaki, Koichi Ogiwara
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Publication number: 20040256075Abstract: A feeder insert is provided for a mold utilized for pouring metal. The insert includes a feeder body having a feed volume, in the form of an inner space, delimited by side walls and a top portion. A feed opening is provided in the base region for communicating with a hollow mold space. A domed feeder cap is displaceably disposed on a feeder body, surrounds the side walls of the feeder body to form an insulating gap, and is fixed in position relative to the feeder body prior to molding of the insert. At least one spacer of flexible material is disposed between the top portions of the feeder body and feeder cap such that during molding of the insert, and placement of the feeder body on the mold surface, due to molding pressure that occurs the feeder cap is displaceable relative to the feeder body while leaving an insulating gap between the top portions of the feeder body and feeder cap.Type: ApplicationFiled: May 20, 2004Publication date: December 23, 2004Inventors: Jurgen-Michael Schafer, Thomas-Michael Schafer
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Patent number: 6805191Abstract: A reduction casting method, in which a molten metal is poured into a cavity of a molding die and casting is performed while the oxide film formed on the surface of the molten metal is reduced by allowing the molten metal and the reducing compound to be contacted with each other in the cavity of the molding die, is characterized in that, at the time the molten metal is poured into the cavity, it is done while it is allowed to be in a turbulent flow.Type: GrantFiled: July 31, 2003Date of Patent: October 19, 2004Assignee: Nissin Kogyo Co., Ltd.Inventors: Keisuke Ban, Koichi Ogiwara, Akira Sunohara
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Publication number: 20040200595Abstract: A method of casting an object, usually a railroad wheel, is provided. A graphite mold having a drag section and a cope section requires a plurality of riser openings in the cope section to ensure proper dimensional accuracy of the cast railroad wheel by allowing molten metal to continue to feed downwardly through the riser openings to the cast wheel cavity during initial cooling. The riser openings are lined with an improved insulating material in an accurate manner such that the insulating material is added between a machined riser opening in the graphite cope mold section and a mandrel inserted in the riser opening.Type: ApplicationFiled: April 14, 2003Publication date: October 14, 2004Inventors: Mark S. Shirley, Michael A. Bland, Joseph A. Cuske
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Publication number: 20040168788Abstract: The invention invention provides an apparatus (10) and a method for reducing the volume of risers, and for the possibility of reducing shrinkage blowhole and porosity in shaped gravity casting. The invention provides an apparatus (10) for producing metal flow/stir in the liquid metal (31), the apparatus (10) comprising at least one electrode (16) for forming a continuously-moving plasma arc (34) over the upper surface of selected riser(s) (12) in metallic casting being cast, a stand (26) for suspending said plasma arc electrode (16) over the upper surface of said risers (12) during the casting process, a second electrode (28) attachable to the liquid metal (31) or the metal being used for casting and a power supply (36) for completion of an electric circuit including said plasma arc (34); and control means (38) connected between said apparatus (10) and said power supply (36).Type: ApplicationFiled: January 20, 2004Publication date: September 2, 2004Inventors: Pavel Dvoskin, Valery Zlochevsky, Dror Nadam
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Patent number: 6752199Abstract: A reduction casting method, in which a molten metal is poured into a cavity of a molding die and casting is performed while the oxide film formed on the surface of the molten metal is reduced by allowing the molten metal and the reducing compound to be contacted with each other in the cavity of the molding die, is characterized in that, at the time the molten metal is poured into the cavity, it is done while it is allowed to be in a turbulent flow.Type: GrantFiled: March 26, 2002Date of Patent: June 22, 2004Assignee: Nissin Kogyo Co., Ltd.Inventors: Keisuke Ban, Koichi Ogiwara, Akira Sunohara
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Patent number: 6745816Abstract: The method of casting of the present invention is capable of making volume of a feeder head can be small and making cooling rate of the feeder head can be easily made lower than that of a cavity. The method is executed in a casting machine, which includes a casting die, in which the feeder head is provided between a metal inlet and the cavity and in which heat insulating of the feeder head is greater than that of the cavity so as to make cooling rate of the feeder head lower than that of the cavity. The method comprises the steps of: pouring a molten metal into the cavity; reacting the molten metal on a deoxidizing compound in the cavity so as to deoxidize an oxide film formed on a surface of the molten metal; and supplementing the molten metal in the feeder head to the cavity when the molten metal in the cavity is solidified and shrinked.Type: GrantFiled: May 10, 2001Date of Patent: June 8, 2004Assignee: Nissin Kogyo Kabushiki KaishaInventors: Keisuke Ban, Akira Sunohara, Yasuhiro Sasaki, Koichi Ogiwara, Sakuzo Nakatani
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Patent number: 6725900Abstract: In the method of deoxidation casting, a disused metal left in a feeder head can be easily removed from a cast product, or the molten metal left in the feeder head can be removed from the cast product so as to easily finish the cast product. The method comprises the steps of: pouring a molten metal into a cavity of a casting die; and reacting a deoxidizing compound with the molten metal so as to deoxidize an oxide film formed on a surface of the molten metal. And the method is characterized in that rate of cooling the molten metal in a feeder head of the casting die is lower than that in the cavity, and that the molten metal in the feeder head, which is not solidified, is treated when the molten metal in the cavity is solidified so as to make an outline of a cast product correspond to that of a desired product.Type: GrantFiled: March 15, 2002Date of Patent: April 27, 2004Assignee: Nissin Kogyo Co., Ltd.Inventors: Keisuke Ban, Koichi Ogiwara, Sakuzo Nakatani, Akira Sunohara
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Publication number: 20040050526Abstract: This present invention concerns a feeder system for a cast piece with a feeder and/or feeder head and a tubular body, characterized in that the tubular body connects the feeder and/or feeder head directly or indirectly with the cast piece and/or the mold cavity.Type: ApplicationFiled: July 24, 2003Publication date: March 18, 2004Inventors: Udo Skerdi, Georg Scheerer
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Publication number: 20030234093Abstract: This invention relates to an improved process for casting a metal by pouring molten metal into and around a mold assembly, where a riser is a component of the mold assembly. The process comprises (a) inserting a riser insert into the cavity of the riser, and (b) then allowing molten metal to flow into the cavity of the riser containing the riser insert. The process is carried out in a manner such that the density and the shape of the riser insert enables the riser insert to float on the surface of the molten metal when the molten metal enters the cavity of the riser.Type: ApplicationFiled: June 20, 2002Publication date: December 25, 2003Inventors: Ronald C. Aufderheide, Ralph E. Showman, William J. Massey
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Patent number: 6640874Abstract: A riser sleeve apparatus (10) for preparing and insulating a passage (14) within which molten metal is accumulated prior to its movement into a mold cavity which includes an inner surface (12) which longitudinally extends between a first end (16) and a second end (18) wherein the inner surface bounds the passage. The riser sleeve further includes an annular lip (20) which is positioned adjacent the second end and extends inward into the passage. When the riser sleeve is positioned about a plug of a pattern, the annular lip deforms to seal the passage at the second end. A process for forming a cast metal article using said riser sleeve apparatus. A process for forming the riser sleeve apparatus.Type: GrantFiled: February 22, 2002Date of Patent: November 4, 2003Assignee: American Metal Chemical CorporationInventors: Jay A. Vorndran, John E. Gotheridge
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Patent number: 6598654Abstract: The molding sand comprises hollow microspheres of aluminum silicate, preferably with an aluminum content between 15 and 45% by weight, a wall thickness between 3 and 10% of the particle diameter and a particle size between 10 and 350 &mgr;m. These sands are useful to manufacture low density cores with good “veining” and penetration characteristics, moreover maintaining the mechanical properties of the core obtained. These cores are useful in the manufacture of iron casting.Type: GrantFiled: July 1, 1999Date of Patent: July 29, 2003Assignee: Iberia Ashland Chemical, S.A.Inventor: Jaime Prat Urreiztieta
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Publication number: 20020139505Abstract: A reduction casting method, in which a molten metal is poured into a cavity of a molding die and casting is performed while the oxide film formed on the surface of the molten metal is reduced by allowing the molten metal and the reducing compound to be contacted with each other in the cavity of the molding die, is characterized in that, at the time the molten metal is poured into the cavity, it is done while it is allowed to be in a turbulent flow.Type: ApplicationFiled: March 26, 2002Publication date: October 3, 2002Inventors: Keisuke Ban, Koichi Ogiwara, Akira Sunohara