Abstract: A radial pattern assembly is disclosed. The assembly includes a hollow sprue comprising a sprue wall disposed about a longitudinal axis, the sprue wall having a thickness, a length and a periphery. The assembly also includes a pattern disposed radially outwardly of the sprue wall. The assembly further includes a radially outwardly extending gate attached to and extending between the sprue wall and the pattern, the hollow sprue, pattern and gate each formed from a fugitive material.

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: Apparatus for the gravity-cast, bottom-fill, “lost foam” casting of metal castings, including a fugitive, pyrolizable pattern (for forming a casting cavity), and a hollow sprue (for conducting melt to the casting cavity) embedded in a bed of loose sand. The sprue is free from pyrolyzable foam and conducts melt from above the pattern to a gating system supplying melt to the pattern. The sprue is constructed so as to cause the melt to approach the gating system from beneath and keep any pyrolysis products from entering the sprue.

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: Fully dense long ingots are produced by the bottom pouring method and apparatus of the present invention. A solidification sequence is achieved which is conducive to eliminating solidification shrinkage and piping. The set-up of the bottom poured ingot molds facilitates a solidification sequence starting from the top and then down the ingot mold and then up the down pour pipe.

Abstract: A bottom casting apparatus comprises a pouring pipe, a stool, molds, and runners, wherein the runner satisfies the following equations (1) and (2) and a gap formed between a side wall of a groove for a runner provided in the stool and a runner brick is filled with heat resisting granules, A−D≦D(Z/100)+2.5 (mm)  (1) A−D>B−E>0  (2) where, A and B are widths (mm) at an upper portion and a bottom portion of the groove, respectively, D and E are widths (mm) at an upper portion and a bottom portion of the runner brick disposed within the groove, respectively, and Z is a mean coefficient of linear expansion (%) of the runner brick in the temperature range of a room temperature to 1000° C.

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: In a string of molds (32) with vertical parting surfaces, each mold cavity (35) is connected through a wide throat with its own after-feeding reservoir (36). When the mold has been poured, a gas pressure is applied through a channel (43) and a passage (41) to a lower metal surface in the after-feeding reservoir (36). This gas pressure is not allowed to exceed the metallostatic pressure in the mold at the surface, at which the pressure is applied, until the metal in the ingate (37) has solidified or the ingate has been blocked in some other way. At the location where the passage (41) opens into the after-feeding reservoir, it is covered by an element (42) that is impermeable to the metal having been poured but permeable to the pressurized gas. When the metal in the ingate (37) has solidified or the ingate has been blocked in some other way, the gas pressure may be increased.

Abstract: A metal wood golf clubhead is formed from a mold which includes an external gate into which molten metal is poured and internal gates in the mold cavity which facilitate flow of the molten metal into all portions of the mold cavity. The internal gates are located in the portion of the mold cavity which forms the interior surface of the top of the clubhead.

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

Abstract: Apparatus and method for countergravity casting a melt employs a particulate mass disposed in a container about a mold having a mold cavity, an ingate passage communicated to the mold cavity for supplying the melt to the mold cavity, and a separate, preformed riser-forming member connected to the mold so as to communicate to an isolated and/or enlarged region of the mold cavity needing additional melt supply during solidification in the mold. The mold ingate passage and a source of the melt are communicated to conduct the melt through the ingate passage to the mold cavity to fill the mold cavity with the melt and form a riser of melt in the particulate mass. The riser of melt provides a source of additional melt for supply, as necessary, to the isolated and/or enlarged region during solidification of the melt in the mold cavity to accommodate melt shrinkage thereat.

Abstract: The mold formed of resin-bonded sand includes a vertical sprue in fluid flow communication with a horizontal chamber reservoir underlying the mold cavity defining the thin wall structure. The thin wall cavity portion is positioned about a common horizontal level above the reservoir. Vertical runners feed the metal from the horizontal reservoir up into the cavity. The number and location of these runners are such as to fill the cavity from several points of entry with uniform temperature metal before any solidification occurs.

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 casting mold is provided for a body frame for a motorcycle including a head pipe for supporting a rotary shaft for a handle, a pair of left and right main body frame elements, connected to the head pipe and extending rearwardly of a car body, a pair of left and right engine supporting members, connected to and extending downwardly from the main body frame elements adjacent to said head pipe, and a horizontally extending frame element connecting said left and right main body frame elements to each other at intermediate portions in the longitudinal direction. The engine is supported at least at a lower end portion of the left and right engine supporting members and intermediate portions in the longitudinal direction of the left and right main body frame elements and an upper end portion of a shock absorber is connected to the horizontally extending frame elements.

Abstract: Molten metal is poured from a melt container to a mold cavity defined by a molding material wherein the molding material in the region of the runner gate is of a higher density with respect to the rest of the molding material. A pouring lip protruding from the melt container seals in the region of the runner gate for delivering molten metal from the melt container to the 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: Apparatus for the shaping of metal in a bottom-gated mold by the vacuum-induced countergravity casting method including an upstanding levee on the periphery of the drag and circumscribing the chamber-to-mold joint and/or the cope-to-drag joint for isolating such joint(s) when the mold is immersed in an underlying melt.

Abstract: A bottom circular tray, a circular top cap and one or more circular disks are coupled thereto, the disks, the top cap and the bottom tray having a common central sprue or cylinder. The plurality of disks form an ascending spiral path from the bottom tray to the top cap. Liquid metal will flow through the central sprue to the bottom tray and up through the ascending spiral path to the top cap and into the mold cavity to form an inclusion free casting.

Abstract: The mold body contains a cavity and at least one vent passage for venting gas from the cavity through the body. The vent passage has a portion of predetermined regular shape extending part-way through the cavity wall defining at one end an inlet portion opening into a portion of the cavity with a substantially greater resistance than the cavity to penetration therein of casting material. The vent passage further has an outlet portion formed by an irregular crack in the mold body extending from an inner end exposed to the inlet portion through the mold body, the crack having one of its transverse cross-section dimensions short enough to prevent leakage of casting material therethrough. The mold is made by forming a partially bonded ceramic material containing a casting cavity and incorporating in a wall of the cavity a vent pattern of a shape to mold the portion of predetermined regular shape of the vent passage.

Abstract: Refractory shapes such as tubular tiles and tubular runners are provided with a novel graphite interior coating penetrating the refractory and forming with the refractory a lining that resists erosion of molten metal flowing therethrough. The coated refractory shapes are particularly useful in forming mold assemblies for bottom pouring.

Abstract: A method for moulding multiple castings in which each mould is fed from a source of molten metal through a thin slit the width of which lies in the range 1.25 mm down to 0.25 mm. The cast articles can easily be removed from the runner and riser system after casting without a machining operation so that the casting moulds can be packed closer together and more castings can be produced from each mould assembly. The thin slit also acts as a filter. A particular mould assembly seen in FIG. 2 is cylindrical and comprises a plurality of wedge-shaped mould segments 2 having mould cavities 4 in abutting faces. A central runner passage 6 is formed when the mould segments are assembled and the metal flows into the mould cavities through narrow slits 10 in one edge of each mould. After casting and removal of the mould the narrow flashing formed in the slits can easily be broken to remove the cast articles from the metal formed in the central runner passage.

Abstract: Casting metal in rigid, self supporting, gas permeable molds with one or more mold cavities for molding one or more parts, in which the mold cavities have gate passages with their lower open ends at the lower surface of the mold, by submerging the lower ends of the gate passages beneath the surface of molten metal and applying a reduced pressure to the upper surface of the mold to fill the mold cavities with molten metal to produce unconnected metal parts or groups of parts.

Abstract: Unitary, rigid, self-supporting, gas permeable, low temperature bonded, sand grain molds having peripheral side surfaces extending between vertically spaced upper and lower surfaces with mold cavity means spaced therebetween connected to gate passage means having lower open ends exposed at said lower surface, adapted to be filled with molten metal through the gate passage means by applying reduced pressure to the top surface of the mold while its lower surface with the gate passage means lower open ends are submerged in molten metal, are provided with enclosed gas collection void means adjacent to and spaced from each of the mold cavity means, the gate passage means and the upper and lower mold surfaces for collecting gases from the cavity means and gate passage means during filling of the cavity means for controlled removal of gases from the void means through the upper mold surface by application of reduced pressure thereto.

Abstract: In a mould assembly for multiple castings each mould is fed from a source of molten metal through a thin slit the width of which lies in the range 1.25 mm to 0.25 mm. The cast articles can be easily removed from the runner and riser system after casting without a machining operation so that the casting moulds can be packed closer together and more castings can be produced from each mould assembly. The thin slit also acts as a filter. A particular mould assembly seen in FIG. 2 is cylindrical and comprises a plurality of wedge-shaped mould segments 2 having mould cavities 4 in abutting faces. A central runner passage 6 is formed when the mould segments are assembled and the metal flows into the mould cavities through narrow slits 10 in one edge of each mould. After casting and removal of the mould the narrow flashing formed in the slits can be easily broken to remove the cast articles from the metal formed in the central runner passage.

Abstract: Guide and runner assemblies for uphill teeming comprise a refractory tube in a sheath with an optional body of particulate material between the inner tube and sheath. The sheath may be combustible.

Abstract: Method and apparatus are provided for loading, in stepwise fashion, hollow cylinders on a recumbent positioned mandrel, for retaining the cylinders on the mandrel during transfer for vertical positioning, and for releasing the cylinders on a seat without disturbing the linear alignment of or dropping the cylinders.

Abstract: An aluminum-diffusion coated steel pipe having an aluminum-coated layer on at least the inner surface of the steel pipe to be in contact with molten metal is used as a gating pipe system in a casting mold comprising a mold body and a gating system for pouring molten metal into the mold body. This aluminum-diffusion coated steel pipe can be further subjected to a secondary heat treatment in a high-temperature oxidizing atmosphere.

Abstract: The invention relates to the units of a pouring system for uphill teeming. Conventionally, such units are formed by a pouring trumpet having a two-part heavy duty iron casing, and by runners set in channels in a heavy cast iron base plate, requiring skillful assembly on site. When unskilled personnel are utilized there is frequently incorrect assembly and positioning, leading to jointing and cracking, faults which in turn leads to molten metal penetration during pouring with consequent damage to the cast iron casing of the trumpet and the case iron base plate with the inherent danger of a complete break-out. The objective of the invention is to alleviate the problems outlined above, that objective being met by providing the units of a pouring system for uphill teeming each comprising an outer casing, an inner refractory liner and a refractory insulating material between the outer casing and the inner liner, each unit being pre-assembled as a complete unit for delivery to a casting bay.

Abstract: In the art of investment casting, a refractory mold characterized by a casting system including a sprue passage, a cup at one end of the sprue passage, a runner extending from the cup and connecting to the sprue passage near its other end, at least one pattern cavity gated into the sprue passage between the ends of the runner, and a refractory wall in the cup dividing it into a pouring cup portion communicating with the runner and another portion communicating with the sprue passage. A pattern set-up designed to make the mold by the "lost pattern" process of investment casting.

Abstract: A method of reducing odors resulting from a ferrous metal molding operation is disclosed. A green sand molding mixture is employed having 1-2% by weight volatile organic material. The mold is provided with manifold-type channels each 0.5 inch in diameter which extend between the upper mold surface to a distance 1-2 inches from the mold cavity. The channels are spaced apart a distance 2-10 inches and at least one of the channels is located 2.5 inches from a pouring basin so that during a metal pouring operation all of the gas flows exiting from said channels will be autoignited and reduce odors by at least 50%.

Abstract: Cast iron ingot mold stools having exceptionally smooth flat surfaces and a longer average life are produced by casting such stools in a mold, the inside of which is formed by rigid thermal insulative boards.

Abstract: A filling apparatus includes a melt container with a bottom outlet spout and an interior closure plug. In certain embodiments the spout has a conical end. A casting mold has a pouring gate and channel. The container is supported by an elevating mechanism and either the container or the mold can also be movable horizontally to permit alignment of the spout and gate. A separatory body is between the spout and gate, several embodiments being disclosed including a layer of material formed on the spout and a conical member in a recess at the gate, the conical member being shaped to receive the conical end of the spout during filling. The separating member of the mold includes a receptacle having a volume greater than the volume of the spout bore below the closure plug to accept melt therefrom after filling.

Abstract: A machine for forming foundry moulds includes a turret supporting spaced mould frames, each of the latter having a mould portion formed therein by rotation of the turret toward a sand filling and compacting station and away therefrom. The completed mould portion may be moved to a position where a core can be set thereon and then moved to a position where the mould portions are positioned one atop another to make a stack of finished and cored moulds. When the moulds are not cored, a pair of said filling and compacting stations are provided, the turret oscillating or rotating unidirectionally from a loading position to a delivery position. Where a pair of filling and compacting stations are provided for forming cope and drag mould portions, the turret oscillates to place the two mould portions in proper position to form a mould comprised of cope and drag portions.

Abstract: A mould assembly for producing multiple castings in which a plurality of mould components are closely arranged together in an array and define a plurality of mould cavities. At the base of the array there is provided a regularly shaped space which communicates with each of the individual mould cavities via a runner passage and thus molten metal admitted to the space fills each of the mould cavities simultaneously leading to uniform properties in all the castings. The individual mould components are preferably injected moulded in a ceramic material.

Abstract: A high melting temperature metal, casting mold is made of sheet metal embedded in a supporting mass of refractory particles preventing deformation of the sheet metal under the weight of the cast metal and conducting heat from the sheet metal at a rate preventing complete melting of the sheet metal.

Abstract: The present invention describes a preformed, multi-part casting mold having a preformed gating system integral therewith for providing smooth, bottom feeding of molten metal to the mold cavity while simultaneously removing contaminants from the metal prior to entry into the cavity. The improved mold is especially useful in casting columnar grained or single crystal metal and alloy articles, such as gas turbine blades.

Abstract: An apparatus for introducing additives into molten metal being poured through a flow path and into a casting cavity of a casting mold includes a wire feed mechanism for feeding a wire of additive material into the molten metal in the flow path for erodibly mixing with the molten metal prior to its entry into the casting cavity. A device is provided for moving the wire feed mechanism relative to the casting mold between a feed position in which the end of the wire of additive material is disposed in the flow path and a second position in which the end of the wire is removed therefrom.

Abstract: A method and apparatus is disclosed for conditioning a charge of molten cast iron, which would normally solidify with a flake graphite structure, to produce partial or total spheroidal graphite cast iron. In addition, the method and apparatus can be used to further condition a partially conditioned cast iron to yield a partial or fully spheroidal graphite cast iron. A recess is provided in the metal flow system (within or without the mold system) leading to the casting cavity or cavities. The recess has a shape and cross-section (taken in directions normal to the direction of flow of the molten charge) such that the spheroidizing agent dissolves uniformly when the molten iron flows over it to achieve unprecedented homogeneity. A dense solid unitary block of spheroidizing or nodularizing agent, substantially devoid of MgO interiorly thereof, is typically snugly fitted in said recess and mates with the side walls and bottom of said recess.

Abstract: An apparatus for introducing additives into a casting mold having a flow path for directing a stream of molten metal into a casting cavity formed within the casting mold, and a mixing chamber in the flow path being in registry with a substantially endless wire of additive material continuously fed into the mixing chamber for erodibly substantially completely mixing with the molten metal flowing through the mixing chamber prior to its entry into the casting cavity.

Abstract: Apparatus for molding, by inoculation, cast iron parts requiring a spheroidal graphite texture, includes a mold containing the impression of the item to be cast and a treatment chamber, situated within the inlet channel of the mold, which opens into the impression of the part. The chamber contains the necessary inoculant for the casting of parts, and the volume of the chamber is equal to the sum of the volumes of the part being cast and the deadhead. The chamber is closed off from the impression portion of the mold by means of a temporary plug which is capable of being destroyed by means of the combined action of the temperature and pressure of the molten metal, the inoculation being performed within this chamber during the time necessary for the destruction of the temporary plug.

Abstract: A radial pattern assembly is disclosed. The assembly includes a hollow sprue comprising a sprue wall disposed about a longitudinal axis, the sprue wall having a thickness, a length and a periphery. The assembly also includes a pattern disposed radially outwardly of the sprue wall. The assembly further includes a radially outwardly extending gate attached to and extending between the sprue wall and the pattern, the hollow sprue, pattern and gate each formed from a fugitive material.