Extracting Pattern In Liquid State Patents (Class 164/35)
  • Patent number: 5113925
    Abstract: A method for forming a metal matrix composite within a mold of investment material. The method comprises the steps of forming a preform mixture of liquid flow medium, binding agent and reinforcement into the desired shape of a metal matrix composite. Then, allowing the preform mixture to solidify into desired shape. Next, encasing the preform mixture within investment material. Then, heating the preform mixture at a controlled rate which first allows any fluid, such as water, to evaporate, then allows removal of the flow medium. Next, sintering the remaining reinforcement material and binder to form a solid preform. Then, forcing molten metal under pressure into said preform. Next, solidifying the molten metal to form a metal matrix composite in the shape of this preform; and removing the investment material from metal matrix composite. Additionally, there is a method comprising the steps of connecting a preform, which has been previously prepared for infiltration of molten metal, to a sprue system.
    Type: Grant
    Filed: October 9, 1990
    Date of Patent: May 19, 1992
    Assignee: PCast Equipment Corporation
    Inventor: Arnold J. Cook
  • Patent number: 5108668
    Abstract: In connection with a device for casting lead grids for electric battery plates, a highly porous ceramic mold lining, preferably of zirconium oxide, is prepared by flame-spraying. Such a lining can include a thin surface coating on a profiled, basic metallic mold or a separately prepared insert plate which is retained to a metallic mold molder. The ceramic surface coating may be accurately formed in place, or may be formed as an over-spray which is then reduced in thickess. Formation of the surface coating may be accomplished by placing masks on the basic metallic mold during the flame spraying, for those areas of the grid which tend to accumulate material, or by adjusting an initially coarse profile of the ceramic layer to the exact profile of the casting by a material-removing treatment.
    Type: Grant
    Filed: August 12, 1986
    Date of Patent: April 28, 1992
    Assignee: Varta Batterie Aktiengesellschaft
    Inventor: Bernhard E. Kallup
  • Patent number: 5088544
    Abstract: An improvement to the process for the lost-foam casting of metal articles. According to the process, the casting takes place under a controlled pressure which initially increases at a rate between 0.003 and 0.3 MPa for a first period of at most 5 seconds from the begining of the rise in pressure. The pressure then increases during a second period at a rate higher than the rate of increase during the first period, until the maximum desired pressure is attained.
    Type: Grant
    Filed: October 9, 1990
    Date of Patent: February 18, 1992
    Assignee: Aluminium Pechiney
    Inventor: Michel Garat
  • Patent number: 5069271
    Abstract: An expendable pattern of an article to be cast comprises a meltable material that expands upon heating (e.g., a wax pattern). The pattern is invested with particulate mold material to form a thin, layered shell having a wall thickness not exceeding about 0.12 inch. The thin shell wall thickness unexpectedly reduces damage and distortion to the shell during removal of the pattern therefrom by steam autoclaving. After firing, the thin gas permeable shell mold is surrounded by a refractory particulate support media in a vacuum housing. The vacuum housing is then evacuated to evacuate the mold cavity defined by the thin shell and concurrently a pressure is applied to the support media so as to compress the support media about the thin shell to support the shell against casting stresses when molten metal is countergravity cast into the evacuated mold cavity.
    Type: Grant
    Filed: February 25, 1991
    Date of Patent: December 3, 1991
    Assignee: Hitchiner Corporation
    Inventors: George D. Chandley, Richard T. Carter
  • Patent number: 5069265
    Abstract: A turbine engine component includes an annular array of airfoils which extend between inner and outer shroud rings. In order to accommodate thermal expansion of the airfoils, space is provided in a shroud ring rail. To provide space in the shroud ring rail, core material is positioned at the ends of the airfoils. The core material may be preformed separetely from the airfoils or may be a coating which is applied to end portions of the airfoils. Wax pattern material partially encloses the end portions of the airfoils and core material. The shroud ring pattern and the core material are covered with ceramic mold material to form a mold. The shroud ring pattern is then removed from the mold to leave the core material disposed in the shroud ring mold cavity at the end portions of the airfoils. As the mold is preheated, bonds between the core material and the airfoils are broken and the core material is gripped between end portions of the airfoils and the ceramic mold material.
    Type: Grant
    Filed: March 26, 1990
    Date of Patent: December 3, 1991
    Assignee: PCC Airfoils, Inc.
    Inventor: William S. Blazek
  • Patent number: 5052463
    Abstract: A pipe section, especially an elbow pipe section, is cast to have an internal heat insulation lining so that the pipe section can withstand temperatures up to about 2500.degree. C. The internal heat insulation is first formed as a hollow casting core of carbon fiber composite material which, after curing, is inserted into a casting mold to function as the casting core which then becomes the internal heat insulation of the pipe section as the result of the casting of the pipe section, whereby the carbon fiber composite material is bonded to the interior surface of the pipe section.
    Type: Grant
    Filed: March 9, 1990
    Date of Patent: October 1, 1991
    Assignee: Messerschmitt-Boelkow-Blohm GmbH
    Inventors: Manfred Lechner, Dieter Kunzmann
  • Patent number: 5016702
    Abstract: Open-celled metal structures are produced which have walls and webs of uniform strength throughout. The structures may also have an irregular surface pattern. To make a strengthened positive pattern, the method comprises application of at least one layer of a strengthening agent such as poly(methyl methacrylate) or polyester resin to a plastic substrate used for ceramic mold formation. The strengthened positive pattern is embedded in a ceramic mass, and heated to incinerate and remove the plastic substrate, which results in voids in the ceramic mass. Molten metal is poured into the ceramic mass. After solidification, the ceramic mass is removed to form the open-celled metal structure.
    Type: Grant
    Filed: August 24, 1990
    Date of Patent: May 21, 1991
    Assignee: Eska Medical Lubeck Medizintechnik GmbH & Co.
    Inventor: Olaf Ahlers
  • Patent number: 5004037
    Abstract: The tube is at least two inches long and has successive sections of progressively smaller diameters to produce a correspondingly shaped sprue passage communicating with a pattern cavity in a casting investment, so that fluid casting material passes with increasingly fluid velocity between an inlet and outlet of the sprue passage during the casting process. A bulbous portion of the tube is spaced from its free end, to form a reservoir chamber in the sprue passage, spaced sufficiently from the pattern cavity, so that casting material flowing through the sprue passage attains maximum velocity at the outlet of the passage entering the pattern cavity.
    Type: Grant
    Filed: August 7, 1989
    Date of Patent: April 2, 1991
    Inventor: Ronald Castaldo
  • Patent number: 4995811
    Abstract: A method for designing and constructing component part removable partial dentures comprising designing the removable partial denture in tooth-supported and tissue-borne components provided with mechanical locks, waxing the design onto an investment model, casting the components, finishing the components, fitting the components onto a master cast, and locking the components together on the master cast or in the patient's mouth to form a single rigid unit using visible light cured resin around and over mechanical locks cast into the frame components.
    Type: Grant
    Filed: March 13, 1989
    Date of Patent: February 26, 1991
    Inventor: Bert T. Cecconi
  • Patent number: 4995443
    Abstract: A method is disclosed for the casting of metals by the use of a consumable or evaporative pattern. In this method, a foamed pattern of a desired part is first formed. The pattern is then dipped into a ceramic slurry and the slurry dried in order to form a shell containing the foamed pattern. A heated bed of a particulate medium is formed around the ceramic shell which causes the pattern to evaporate and form a mold. A molten metal is then introduced into the mold, solidified and removed from the mold to form a casting.
    Type: Grant
    Filed: February 8, 1989
    Date of Patent: February 26, 1991
    Assignee: The Board of Trustees of Western Michigan University
    Inventor: Jay Easwaran
  • Patent number: 4993472
    Abstract: A novel sprue is used to cut wax and obtain the impressions of finger or other digit prints in a quick and effective manner. The sprue has an elongated handle connected to an impression plate having walls on its perimeter which cut easily through thin layers of wax when downward pressure is applied on the bottom of the impression plate. Then the wax is heated by a heat lamp until the top surface is melted at which time a finger or digit is placed on the wax and with downward pressure applied until an impression of the fingerprint or other digit print is left in the wax. After the wax is cooled then the impression can be imparted in gold or other metal jewelry by standard jewelry casting techniques. The result of this method is a memento that can be attached and worn as a necklace, bracelet, ring or other item of jewelry.
    Type: Grant
    Filed: June 18, 1990
    Date of Patent: February 19, 1991
    Inventor: Kirk L. Culver
  • Patent number: 4987944
    Abstract: A turbine engine component having an annular array of airfoils disposed between inner and outer shroud rings is made by a method which includes molding bodies of positioning material around central portions of the airfoils. The bodies of positioning material are placed in an annular array. Inner and outer shroud ring pattern dies cooperate with the bodies of positioning material to form inner and outer shroud ring pattern mold cavities. Pattern material is injected into the inner and outer shroud ring pattern mold cavities. The pattern material engages the airfoils, the positioning material, and the shroud ring pattern dies. The pattern material is solidified to form one piece annular inner and outer shroud ring patterns. The shroud ring patterns are covered with a ceramic mold material to form a mold. The inner and outer shroud ring patterns are then removed from the mold to leave shroud ring mold cavities.
    Type: Grant
    Filed: November 13, 1989
    Date of Patent: January 29, 1991
    Assignee: PCC Airfoils, Inc.
    Inventor: Paul L. Parks
  • Patent number: 4986333
    Abstract: The ceramic core is located within the ceramic mold by the insertion of recrystallized alumina pins through the wax encasing the core prior to encasing the whole in a ceramic slurry; on the subsequent removal of the wax, the molten metal, i.e. superalloy, is injected into the resulting space; the recrystallized alumina pins remain intact during the casting process hence substantially increasing the success rate of achieving accurate core locating during casting solidification.
    Type: Grant
    Filed: January 10, 1989
    Date of Patent: January 22, 1991
    Assignee: Rolls-Royce, plc
    Inventor: Frederick H. Gartland
  • Patent number: 4984620
    Abstract: The apparatus comprises two containers, which are adapted to be connected to a vacuum pump. The upper container contains a rotationally symmetrical guiding body. A distributing space is defined by the shell of the upper container and the closed peripheral surface of the guiding body and extends from the cover of the upper container to pipe lengths, which terminate at their lower end over cups arranged in the lower container. As a result, the apparatus permits an economical making of molds in series and meets the requirements arising in practice regarding the batchwise processing of batches in quantities which vary within an extremely wide range.
    Type: Grant
    Filed: May 23, 1989
    Date of Patent: January 15, 1991
    Inventor: Christina Assfalg
  • Patent number: 4981167
    Abstract: The conventional investment casting technique is modified to cast metal products where the product has one or more support portons and at least one feeding tube for feeding molten metal into the cast of the product comprising providing a source of molten metal, connecting at least one metal feed tube to the mold of the metal product to be cast, of forming a hole in each support portion wherein the hole in each support portion is much larger than the volume of metal that can be non turbulently transmitted in a deflected manner into the mold by the feed tube so that the metal poured nto the generally uniform cross section mold cools gradually so that the support portions of the cast metal products will have a generally homogenous composition without air bubbles or cracks which could weaken the product.
    Type: Grant
    Filed: November 30, 1989
    Date of Patent: January 1, 1991
    Inventor: Steve Anderson
  • Patent number: 4972897
    Abstract: Apparatus useful in forming a mold from a wax pattern in an investment casting process, the invention provides a loop element having arm elements which spiral downwardly from and inwardly of the loop element to a base element. Sprue pins mount wax patterns to the loop element in a casting process known as the "lost wax" technique, the apparatus of the invention being particularly useful in the environment of a dental laboratory for formation of crowns and the like of high density. The loop element and arm elements of the apparatus leave channels in the investment material on "burn out" which quickly accelerate a casting material, such as a metal alloy, into the formed mold or molds with a reduction of turbulence which results in fewer defective castings. The channel geometry provided by the apparatus provides benefits due to a lack of right angles or sharp corners which restrict the flow of casting material into the mold or molds.
    Type: Grant
    Filed: February 2, 1990
    Date of Patent: November 27, 1990
    Assignee: MDS Products Inc.
    Inventor: William R. Thomas
  • Patent number: 4966220
    Abstract: A method of casting utilizing an evaporable foam system with a hypereutectic aluminum silicon alloy. The molten alloy is introduced into a mold in contact with an evaporable foam pattern formed of polystyrene, or the like. The heat of the molten alloy will decompose and vaporize the pattern and the vapor will enter the interstices of the surrounding sand, while the molten alloy will fill the void caused by the vaporization of the pattern. By casting the molten alloy into contact with the evaporable foam material, a more uniform distribution of primary silicon is obtained in the cast alloy and the heat of crystallization caused by precipitation of silicon crystals on solidification of the alloy will temporarily slow the solidification rate of the alloy, thus increasing the time for elimination of pattern residue vapors from the molten alloy.
    Type: Grant
    Filed: April 14, 1989
    Date of Patent: October 30, 1990
    Assignee: Brunswick Corporation
    Inventors: William G. Hesterberg, Raymond J. Donahue, Terrance M. Cleary
  • Patent number: 4966225
    Abstract: A ceramic shell mold and method of making the same. The ceramic shell mold includes a facecoat layer comprised of a first ceramic material. A plurality of alternating layers are formed overlaying the facecoat layer. The alternating layers are comprised of a second ceramic material and a third ceramic material, the third ceramic material having thermophysical properties different than the second ceramic material. The second ceramic material and the third ceramic material are preferably a zircon-based material and an alumina-based material, respectively. The resultant ceramic shell mold has a greater high temperature creep resistance than a shell mold formed solely from the second ceramic material or solely from the third ceramic material.
    Type: Grant
    Filed: April 20, 1990
    Date of Patent: October 30, 1990
    Assignee: Howmet Corporation
    Inventors: Paul R. Johnson, Eliot S. Lassow
  • Patent number: 4962909
    Abstract: A casting mold for the production of muffles which serve for the conversion of wax models to metal, with the casting mold having a funnel shaper (1) which consists of a disk-shaped base plate (4), at the circumference of which a side wall (5) which stands vertical to the base plate (4) runs, and a cone (6) arranged in the center of the base plate (4), pipe-shaped, muffle ring (2) partially inserted into the funnel shaper (1), with the outside wall of the muffle ring (2) resting against the inside circumference of the side wall (1) of the funnel shaper (1), a cylindrical ring (7) which is inserted on the side of the muffle ring (2) which faces the funnel shaper (1) and the central opening (8) of which surrounds the cone (6), and a blind funnel (3) provided on the side of the muffle ring (2) opposite the funnel shaper (3), whose funnel tip faces towards the cone (6 ) of the funnel shaper (1).
    Type: Grant
    Filed: January 12, 1989
    Date of Patent: October 16, 1990
    Inventor: Wolfgang Kohler
  • Patent number: 4961459
    Abstract: An improved turbine engine component includes an annular array of airfoils which extend between inner and outer shroud rings. In order to accommodate thermal expansion of the airfoils, cavities are provided in one of the shroud rings. The cavities may be formed by moving a shroud ring under the influence of forces applied to the shroud ring by a gating system. The cavities which are formed in the shroud ring to accommodate thermal expansion of the airfoils may be open-ended, completely closed-ended or partially closed-ended. When a turbine engine component having cavities in an inner shroud ring is to be formed, molten metal in an outer shroud ring mold cavity is first solidified to firmly grip outer ends of the airfoils. The molten metal in an inner shroud ring mold cavity is then solidified. As the molten metal in the inner shroud ring mold cavity solidifies, the gating system contracts to pull the metal in the inner shroud ring mold cavity inwardly relative to the airfoils.
    Type: Grant
    Filed: June 9, 1989
    Date of Patent: October 9, 1990
    Assignee: PCC Airfoils, Inc.
    Inventor: William S. Blazek
  • Patent number: 4955423
    Abstract: A turbine engine component includes an annular array of airfoils which extend between inner and outer shroud rings. In order to accommodate thermal expansion of the airfoils, space is provided in a shroud ring rail. To provide space in the shroud ring rail, core material is positioned at the ends of the airfoils. The core material may be preformed separately from the airfoils or may be a coating which is applied to end portions of the airfoils. Wax pattern material partially encloses the end portions of the airfoils and core material. The shroud ring pattern and the core material are covered with ceramic mold material to form a mold. The shroud ring pattern is then removed from the mold to leave the core material disposed in the shroud ring mold cavity at the end portions of the airfoils. As the mold is preheated, bonds between the core material and the airfoils are broken and the core material is gripped between end portions of the airfoils and the ceramic mold material.
    Type: Grant
    Filed: January 25, 1989
    Date of Patent: September 11, 1990
    Assignee: PCC Airfoils, Inc.
    Inventor: William S. Blazek
  • Patent number: 4951732
    Abstract: An iron metal traverse drum having extremely thin walls is formed by instantaneously injecting a molten metal into a limited cavity of a mold having a form corresponding to the traverse drum in an oxygen-free atmosphere.
    Type: Grant
    Filed: April 18, 1989
    Date of Patent: August 28, 1990
    Assignee: Murata Kikai Kabushi Kaisha
    Inventor: Shoji Yamada
  • Patent number: 4947926
    Abstract: An investment compound for use in a precision casting mold comprises MgO powder and Al.sub.2 O.sub.3 powder as main constituents in such a manner that the MgO powder and/or the Al.sub.2 O.sub.3 powder are or is in the range of 100 .mu.m or less in grain size and of 10% or more in weight precent, whereby even when a high-temperature active casting material such as titanium is used, the material provides a casting having a very beautiful surface with no bubbles formed therein and can positively compensate for shrinkage due to the solidification of cast material in a lost-wax process and can advantageously provide the casting at lower prices.
    Type: Grant
    Filed: October 20, 1989
    Date of Patent: August 14, 1990
    Assignee: Kabushiki Kaisha Morita Seisakusho
    Inventors: Sekiya Ogino, Mikinori Nishimura
  • Patent number: 4940072
    Abstract: Pattern material, such as wax, is removed from an investment casting mold by vapor phase-condensation heating with a fluorochemical boiling at a temperature above the melting point of the pattern material.
    Type: Grant
    Filed: May 31, 1989
    Date of Patent: July 10, 1990
    Assignee: Air Products and Chemicals, Inc.
    Inventors: Mark A. Pellman, Paul T. Kilhefner, III, Terrence S. Hahn
  • Patent number: 4921038
    Abstract: A process for preparing an investment casting mold is provided. A kneaded compound composed of an aggregate and an organic binder is cast into a core molding mold to be solidified therein to produce a core matrix which is impregnated with a heat resisting binder to an appropriate depth followed by coating with a wax, whereby a core mold is formed. The core mold is placed in position within a lost model molding mold followed by injection of a lost model forming material. A slurry and stucco particles are alternately coated over the lost model for plural times to form a refractory layer. The lost model is removed to obtain a final mold which is baked to effect simultaneous baking of the core mold and the refractory layer, the former forming the mold core and the latter forming the exterior shell mold.
    Type: Grant
    Filed: May 19, 1989
    Date of Patent: May 1, 1990
    Inventors: Nobuyoshi Sasaki, Susumu Baba
  • Patent number: 4919193
    Abstract: A core mold to be assembled with a shell mold for use in an investment casting process is provided. The core mold comprises a core matrix essentially consisting of an aggregate and an inorganic binder, a binder layer impregnated from the surface of said core matrix, a coating layer formed by coating a slurry over said binder layer, and a paraffin wax layer covering the exterior periphery of said coating layer. Also provided are a process for preparing the core mold and a process for preparing an investment casting mold in which the core mold is assembled.
    Type: Grant
    Filed: March 31, 1989
    Date of Patent: April 24, 1990
    Inventor: Nobuyoshi Sasaki
  • Patent number: 4905750
    Abstract: The forming of a wax or sacrificial pattern for investment castings in which the interior ceramic reinforced passageway forming elements are reinforced with a metallic wire, and sheathed in a quartz material is disclosed. Thereafter the wire and quartz serve as a reinforced core around which the ceramic is molded to the configuration of the passageway, and in addition containing the positioning elements for mating engagement with the wax injection die at each end of the passage forming part. The method of forming the pattern for injection molding involves the steps of first determining the passage locations, and thereafter forming a reinforced passage ceramic forming member to be positioned interiorly of the pattern. The wax injection die is formed with mating elements to support the ceramic passage forming members. Thereafter the mold is filled with sequential layers of ceramic, and fired.
    Type: Grant
    Filed: August 30, 1988
    Date of Patent: March 6, 1990
    Assignee: Amcast Industrial Corporation
    Inventor: Walter S. Wolf
  • Patent number: 4872500
    Abstract: A method of manufacturing a composite chip-removing tool which includes a tool body of a material which is in its molten state above a predetermined melting temperature, and at least one tipping element secured to the tool body, comprises positioning the tipping element on a model of the tool body that consists of a material that melts at a temperature considerably lower than the predetermined melting temperature, in a position relative to the model which the tipping element is to assume relative to the body, and simultaneously forming the tool body and a durable mechanical connection of the tipping element to the tool body in a precision casting operation involving replacement of the material of the model with the material of the tool body in its molten state. The model may be produced prior to or simultaneously with the positioning of the tipping element on the model.
    Type: Grant
    Filed: October 14, 1986
    Date of Patent: October 10, 1989
    Inventors: Donald Duffey, Sellers Hardee, Wayne Smith, James Elliott, Robert Gardner, Claus Suess
  • Patent number: 4844144
    Abstract: A method of investment casting utilizes a pattern produced by stereolithography in which a three-dimensional specimen is provided by light cure of ethylenically unsaturated liquid material. The stereolithography composition is constituted by the ethylenically unsaturated liquid material in admixture with an inert low thermoplastic material which weakens the pattern when heated within the mold used in the investment casting process to prevent the thermal expansion of the pattern from cracking the mold.
    Type: Grant
    Filed: August 8, 1988
    Date of Patent: July 4, 1989
    Assignee: DeSoto, Inc.
    Inventors: Edward J. Murphy, Robert E. Ansel, John J. Krajewski
  • Patent number: 4842243
    Abstract: Apparatus for molding hollow metalwood golf club heads of wax or other material with variations in the lie angle of the neck or hosel relative to the body of the club head, in which two molds with communicating mold cavities are supported for turning of one mold about a pivotal axis to change the angular relationship of the two cavities. The molds have arcuate abutting surfaces coaxial with the pivot for effective meeting relationships in the different positions, the hosel base being slightly oversize to accommodate the displacement, and two core pieces in the molds have part-spherical abutting surfaces, also coaxial with the pivot for effective "kissing off" of the parts. The movable mold is detented in one of eight different positions, in one-degree increments. Another embodiment produces solid-headed irons with selected different lie angles of the hosel, but with only one core piece, which is in the hosel mold.
    Type: Grant
    Filed: January 19, 1988
    Date of Patent: June 27, 1989
    Assignee: Lie Angle Solutions, Inc.
    Inventor: Byron Butler
  • Patent number: 4830083
    Abstract: The present invention relates to a mold material for casting pure titanium or a titanium alloy which comprises one or more chief materials selected from among silica-alumina mixtures, mullite and spinel and a hardening agent comprising a phosphate and a basic metal oxide and a process for casting pure titanium or a titanium alloy by the use of said mold material. This mold material forms a refractory structure having a melting point higher than that of pure titanium or a titanium alloy therein to enable pure titanium which is unstable in a molten state to be cast stably.
    Type: Grant
    Filed: September 16, 1987
    Date of Patent: May 16, 1989
    Assignee: Ohara Co., Ltd.
    Inventor: Seizo Nakamura
  • Patent number: 4825934
    Abstract: A cushioning sheet made of a flammable material for use, e.g. in denture casting. It is inserted into a casting frame and adapted to burn out when heated to leave a space between a casting frame and a casting mold in the frame. The space serves to absorb the difference in the thermal expansion between the frame and the mold, thus preventing the casting mold from cracking or breaking. The cushioning sheet is formed with apertures. The casting material penetrates through the apertures, abutting against the casting frame to support the casting mold upon the frame even after the cushioning sheet has burnt out.
    Type: Grant
    Filed: October 14, 1987
    Date of Patent: May 2, 1989
    Inventor: Satoshi Kai
  • Patent number: 4811778
    Abstract: The pins which are used for the support of a core in a lost wax casing process are provided with caps. The caps provide sufficient surface area for encapsulation by ceramic slurry. Heat loss from the metal melt via the pins is thus obviated along with undesirable grain nucleation.
    Type: Grant
    Filed: April 4, 1988
    Date of Patent: March 14, 1989
    Assignee: Rolls-Royce PLC
    Inventors: David J. Allen, Joseph Martin, Peter E. Rose, John Terry
  • Patent number: 4800635
    Abstract: A mold is made from a flute chimney model having a precision bore, and a chimney is cast from the mold with substantially no shrinkage in bore diameter. The mold can be made from a chimney model having an entire undercut surface thereon, and the chimney cast with substantially no shrinkage in undercut diameter.
    Type: Grant
    Filed: November 5, 1985
    Date of Patent: January 31, 1989
    Inventor: Sanford Drelinger
  • Patent number: 4793045
    Abstract: A method of forming a bezel that contacts and/or substantially envelops a gem without altering the same is presented. A replica of the gem is initially formed about which a temporary bezel is crafted having the desired artistic markings thereon. In a lost wax process, the temporary bezel is replaced by a permanent bezel. Then the replica is destroyed. In another aspect of the present invention, a replica mold material for use in this process is also disclosed.
    Type: Grant
    Filed: November 21, 1986
    Date of Patent: December 27, 1988
    Inventor: Steven M. Singer
  • Patent number: 4787439
    Abstract: The invention concerns a composition for making a coating consisting essentially of a refractory material selected from the group consisting of yttrium oxide, zirconium oxide, fused yttrium oxide, fused zirconium oxide, fused stabilized zirconium oxide, and fused mixtures of zirconium oxide and yttrium oxide; and a sufficient amount of an yttria sol binder. The composition can be used to prepare refractory materials, casting and core molds.
    Type: Grant
    Filed: November 24, 1986
    Date of Patent: November 29, 1988
    Assignee: Remet Corporation
    Inventor: Roy C. Feagin
  • Patent number: 4766948
    Abstract: Improved small dendrite arm spacings and good technical values, regarding the technical properties of aluminum alloys, particularly tensile strength, yield strength and elongation percent, can be reliably obtained by refining the grain of the casting to provide the smallest possible spacings between the secondary dendrite arms, by casting the aluminum alloys in a ceramic mold provided with numerous micro-sized rough spots and pores and to the inner wall of which mold after it is dried and fired has been applied a thin layer of a salt mixture in which the cations are primarily from the alkalis and/or alkaline earths and the anions are primarily from halogens and which applied salt mixture has a liquidus temperature lower than the casting temperature of the alloy.
    Type: Grant
    Filed: October 15, 1987
    Date of Patent: August 30, 1988
    Assignee: Thyssen Industrie AG
    Inventors: Friedrich Behr, Heinrich Ballewski, Wolfgang Grossmann
  • Patent number: 4754798
    Abstract: The sand-binder mixture in a sand casting mold is controlled so that it contains sufficient binder to enable it to set to form a mold, yet the resulting set mold is sufficiently porous to receive liquids and vapors from a disposable pattern and sufficiently rigid to retain the pattern shape after the pattern is removed. At the proper binder loading, the mold has porosity such that the pattern will evacuate the cavity prior to casting when heated at relatively low temperatures (well below pattern combustion temperatures) that do not harmfully affect the mold and do not necessarily remove all of the pattern material from the mold. Thus, the pattern is removed from the mold cavity, before the molten metal is added, by heating the pattern and mold to cause the pattern to become fluid and to flow both into the sand mold and out of openings in it, without the need for high temperature combustion. The molten metal is then added to the cavity, and allowed to solidify before it is removed.
    Type: Grant
    Filed: September 15, 1987
    Date of Patent: July 5, 1988
    Assignee: Metal Casting Technology, Inc.
    Inventors: George D. Chandley, Rodney G. Riek
  • Patent number: 4751954
    Abstract: A method for selectively coating inexpensive accessories with expensive multi-metals sequentially by utilizing an apparatus of a cylinder member, standing member, wax rod, and glass housing for producing fine products which are coated with colorful expensive multi-metals.
    Type: Grant
    Filed: July 24, 1987
    Date of Patent: June 21, 1988
    Inventor: Jae H. Kim
  • Patent number: 4745961
    Abstract: Time-consuming steps of drying the unhardened and porous refractory dental model, hardening the dried model, and applying multiple coatings of a lacquer spray onto the hardened model are eliminated by spraying the unhardened and porous model with a non-viscous solution of specified cyanoacrylates to thereby produce a final model which yields a mold providing an improved alloy casting dental prosthesis.
    Type: Grant
    Filed: March 18, 1987
    Date of Patent: May 24, 1988
    Assignee: J. F. Jelenko & Co.
    Inventor: Anthony R. Salandra
  • Patent number: 4741378
    Abstract: An improved sprue pin for producing castings by the lost wax method wherein the sprue pin gradually decreases in external circumference toward the tip of the sprue. The length and gauge of the sprue is such that it provides acceptable flow rates and solidification times for new base metal and palladium alloys. A set of lines about the circumferentially decreasing tip allows the user to conform the sprue to the size of the wax pattern being used to form the casting.
    Type: Grant
    Filed: September 20, 1985
    Date of Patent: May 3, 1988
    Assignee: Dentifax International, Inc.
    Inventors: Melvin A. Engelman, Victor Zamaloff, Lori D. Cooke
  • Patent number: 4732204
    Abstract: A process is disclosed for the preparation of ceramic cores which includes injection by means of a press of low power of liquid wax into cavities of a ceramic core disposed in a mould of elastomer produced by moulding of a dummy core which is a replica of the core to be produced.
    Type: Grant
    Filed: February 26, 1987
    Date of Patent: March 22, 1988
    Assignee: Societe Nationale d'Etude et de Construction de Moteurs d'Aviation, "S.N.E.C.M.A."
    Inventor: Jacky P. Tabardin
  • Patent number: 4730657
    Abstract: Both a pattern member and a body of expansion material are covered with a layer of ceramic mold material. The body of expansion material has a coefficient of thermal expansion which is greater than the coefficient of thermal expansion of the ceramic mold material. The layer of ceramic mold material and the body of expansion material are heated. This results in a cracking of the layer of ceramic mold material by the body of expansion material due to greater thermal expansion of the body of expansion material as it is heated. During the step of heating the ceramic mold material and body of expansion material, the pattern member is melted to separate the pattern from the layer of ceramic mold material.
    Type: Grant
    Filed: April 21, 1986
    Date of Patent: March 15, 1988
    Assignee: PCC Airfoils, Inc.
    Inventors: Daniel P. Carson, Francis E. Cozza
  • Patent number: 4728258
    Abstract: To form a turbine engine component, metal airfoils are positioned in an annular array. Outer end portions of the airfoils are embedded in a wax outer shroud ring pattern and inner end portions of the airfoils are embedded in a wax inner shroud ring pattern. A mold is formed by covering the metal airfoils and the shroud ring patterns with ceramic mold material. The wax of the shroud ring patterns is then removed from the mold to leave inner and outer shroud ring mold ring cavities. The shroud ring mold cavities are filled with molten metal which is solidified to form inner and outer shroud rings interconnecting the airfoils. To accommodate thermal expansion of the airfoils relative to the shroud rings, a slip joint is provided between at least one end portion of each of the airfoils and a shroud ring. To enable the slip joint to be formed, molten metal solidifies in the shroud ring to be formed, molten metal solidifies in the shroud ring cavities free of metallurgical bonds to the airfoils.
    Type: Grant
    Filed: April 25, 1985
    Date of Patent: March 1, 1988
    Assignee: TRW Inc.
    Inventors: William S. Blazek, Jerry L. Hasch
  • Patent number: 4712605
    Abstract: A process for producing a hollow metal cast product having a desired interior contour is provided. The process comprises the steps of preparing a first lost model having an outer contour substantially corresponding to a desired interior contour of the finished product, depositing a metallic or ceramic material or a mixture thereof over the surface of said first lost model by spraying to form a layer defining a hollow core block, placing said hollow core block in a first mold, pouring or injecting a material for forming a second lost mold into said first mold to form a second lost model, coating a refractory material over said second lost model to form a second mold for casting, removing second lost mold to form a cavity, casting a molten metal or alloy into said cavity, and staving said second mold to take out a finished product.
    Type: Grant
    Filed: January 12, 1987
    Date of Patent: December 15, 1987
    Assignee: M.C.L. Co., Ltd.
    Inventors: Nobuyoshi Sasaki, Susumu Baba, Hisahiro Arai
  • Patent number: 4709741
    Abstract: The present invention relates to a mold material for casting pure titanium or a titanium alloy which comprises one or more chief materials selected from among silica-alumina mixtures, mullite and spinel and a hardening agent comprising a phosphate and a basic metal oxide and a process for casting pure titanium or a titanium alloy by the use of said mold material. This mold material forms a refractory structure having a melting point higher than that of pure titanium or a titanium alloy therein to enable pure titanium which is unstable in a molten state to be cast stably.
    Type: Grant
    Filed: December 2, 1985
    Date of Patent: December 1, 1987
    Assignee: Ohara Co., Ltd.
    Inventor: Seizo Nakamura
  • Patent number: 4687178
    Abstract: A wax ring tube used in manufacture of a ring-like ornament by casting it using a lost-wax process. Plotting graduations are formed on inner peripheral wall surface of a hole bored along the lengthwise direction of a wax ring tube body.
    Type: Grant
    Filed: January 31, 1986
    Date of Patent: August 18, 1987
    Inventor: Yasuo Kuramoto
  • Patent number: 4682643
    Abstract: An investment casting process employs a low-cost plastic pattern manufactured by machining. A mold is cast around the plastic pattern following which the pattern is removed from the mold to leave a mold cavity which molten metal or the like may be poured to produce a finished part. Reusable plastic patterns may be formed by casing silastic rubber. The silastic rubber patterns may be mechanically separated from the mold without damaging the pattern.
    Type: Grant
    Filed: October 3, 1985
    Date of Patent: July 28, 1987
    Assignee: Nu Con Corporation
    Inventors: David L. Bernhardt, Neno T. Nenov
  • Patent number: 4676294
    Abstract: Gate is a wax structure for forming part of a wax master in investment casting of a dental prosthesis. The gate has a square feeder with a circular disc on each end. The square feeder reduces the cracking stresses between adjacent feeders to reduce unwanted fins, and the square shape aids in final cutoff of the cast prosthetic. In the wax master, one of the discs is secured to the prosthetic form and the other disc to the conventional reservoir bar. The disc shape aids in filleting to the form and bar.
    Type: Grant
    Filed: September 9, 1985
    Date of Patent: June 30, 1987
    Inventor: Robert P. Berger
  • Patent number: 4653568
    Abstract: A foundry process and associated apparatus for providing mixing of water, an additive, and a casting (investment) for the automated powder, which once mixed, are to be delivered to molds to form casting molds such as in the fabrication of microwave components (castings). The apparatus comprises a source of water, a source of additive and a source of the casting powder. There is provided a mixing bowl and automatic control means for coupling the water and additive to the mixing bowl and thereafter delivering the investment powder to the mixing bowl to provide for the thorough mixing of all of these components. The mixing bowl has associated therewith a manually operated valve which permits delivery of the mixed material into flasks disposed in a mixing chamber disposed under the mixing bowl. In accordance with the control provided in accordance with the invention, the mixing occurs initially without vacuum over a first predetermined period of time which may be on the order of 1-3 minutes.
    Type: Grant
    Filed: March 17, 1983
    Date of Patent: March 31, 1987
    Assignee: Fabraze, Inc.
    Inventor: Joseph Baldelli