Abstract: A system and method of increasing a cooling rate of a metal sand casting during solidification. The system includes a 3-D printed manufactured sand mold defining a mold cavity, a coolant inlet port extending into the manufactured sand mold, a myriad of coolant passageways surrounding a portion of the mold cavity, and a coolant outlet port in fluid communication with the coolant passageways. The system further includes a coolant vapor extraction system having a collection manifold in fluid connection with the outlet port of the sand mold. A molten metal is poured into the mold cavity and a liquid coolant is introduced into the sand mold. The liquid coolant changes state into a gas phase as it permeates through the sand mold, thereby increasing the cooling rate of the casting. The liquid coolant may be that of a liquid nitrogen.

Abstract: A holder block system suitable for producing metal castings. The holder block system includes a holder block primary mold that has one or more cavities that accept a sub-mold that incorporates the features of the part to be cast, wherein the sub-mold can be produced utilizing 3-D printing. Methods of preparing holder block patterns and cast objects are with the holder block system disclosed.

Abstract: A casting mold with rigging for casting a railcar coupler, which includes a shank portion and a head portion, includes cope and drag portions that define an external shape for each of at least two couplers. The couplers are nested together and oriented in opposite directions to one another along respective longitudinal axes. A down sprue is centered between the first and second couplers and is configured to direct molten material to a gating system positioned between the at least two couples.

Abstract: 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.

Abstract: A mold that can prevent molten metal from leaking out of it as well as from leaking onto a parting plane of the mold. The mold includes a lower mold having a concave portion that has the shape of a product, into which the amount of molten metal required to produce a casting is poured and an upper mold comprising a convex portion that has the shape of the casting, and forming a cavity that molds the casting, when the upper mold overlaps the lower mold. A structure is formed so as to have certain clearances between the lower mold and the upper mold such that molten metal is prevented from leaking onto the parting plane that is formed where the upper mold and the lower mold overlap, when the casting is produced.

Abstract: A piston for an internal combustion engine has annular cooling passage arranged in the vicinity of the piston crown and radially on the outside, which, in those regions of the pin bosses which lie close to the boss holes, has boss cooling passages which are connected to the cooling passage and are intended for improved cooling of the pin bosses.

Abstract: In-Place Cope Molding or “IPCM,” is designed to reduce or eliminate certain inefficiencies present in traditional molding techniques during production of the cope half of a sand mold. IPCM allows the cope half of the mold to be produced on top of the drag half of the mold by use of a separation barrier which supports the sand above the mold cavity in the drag. This method reduces or eliminates parting line flash, and also avoids the need to turn over or otherwise handle the cope, allowing the cope to be made thinner than a traditional cope and allowing for lower material costs.

Abstract: A part for casting obtained by converting base paper for paper tubing into a tube and containing an organic fiber, an inorganic fiber, and a binder. The part is preferably obtained by winding the base paper into tubing. The part preferably contains 10 to 70 parts by weight of the organic fiber, 1 to 80 parts by weight of the inorganic fiber, 10 to 85 parts by weight of the binder. The organic fiber is preferably pulp fiber.

Abstract: A heat exchanger element obtained by sand casting, having a modular structure and comprising a right head module, a left head module, and at least one optional intermediate module.

Abstract: A casting device includes a wall which is formed in the manner of a sandwich structure from a front layer, a yielding intermediate layer and a supporting outer layer. In this way, the contraction-related internal stresses which occur during cooling are kept at a low level by the resilient properties of the intermediate layer. As such, the formation of cracks in the component to be cast can be avoided.

Abstract: The invention relates to a camshaft made of cast steel having an inner cavity with a cylindrical inner shape, especially a profiled cylindrical inner shape produced rationally according to a lost-foam casting method known per se. A steel camshaft thus produced exhibits a long service life and can withstand extremely high hertzian surface pressures on its bearing surfaces without any damages.

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

Abstract: Thin wall lightweight panels which are subjected to high temperature solutioning and rapid quenching to impart high strength properties without distortion, warping or oil-canning. The panels are produced by casting in a mold cavity having an interconnected recess network which surrounds thin wall-forming areas and distributes molten metal uniformly thereto. The recess network forms a waffle pattern reinforcing rib network surrounding the thin-wall areas, lending strength and dimensional stability thereto during the heat treatment and quenching steps, to prevent distortion, warping and oil-canning.

Abstract: The invention concerns a new material for molding elements as well as the molds produced in this manner. This material contains more than 30% vitreous fused silica and various adjuvants and binders and presents the advantage of the possibility of modulating the thermal conductivity of the molds. Application to all types of industries utilizing shaping by molding of liquid or paste-like materials, or by the hot deformation of flat products.

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

Abstract: A metal casting mold formed of a ceramic material. The mold is reusable and is formed of a crystalline ceramic whose coefficient of thermal expansion (in the range 0.degree. to 1000.degree. C.) is between about 0 and 15.times.10.sup.-7 /.degree.C./ The mold interior surface includes at least one projection extending towards the mold cavity. The projection is provided with a release (draft) angle of about 6.degree., tapering away from the base of the projection. Upon pouring, the molten metal surrounds at least a portion of the projection. Upon cooling within the mold, shrinkage of the metal casting against the tapered sides of the projection forces the casting along the projection, toward the latter's tapered end and away from the mold interior surface and thus partially out of the mold cavity. A method of making the ceramic mold of this invention is also disclosed.

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

Abstract: An adhesive paste for adhering two or more objects, a composite assembly comprising two or more elements bonded by such paste, and a process for preparing cast metal articles using such paste are provided. The adhesive paste comprises an aqueous solution of a specific alkali phenol-formaldehyde resin and a hardener for that resin, wherein the paste prepared by mixing the resin and hardener has a viscosity, as mixed, in the range of about 1,000 cps to about 15,000 cps. The composite assembly comprises at least two separate elements bonded by the adhesive paste of the invention. The process uses a mold or core assembly having at least two separate elements.

Abstract: Inserts with projections and recesses are provided for securement to mold components and also are arranged to make respective recesses and projections in impression material such as sand. These recesses and projections in the impression material are dimensioned and shaped to have a reverse interfitting engagement to accomplish anti-shift functions and are dimensioned and arranged to form spaces between facing impression portions for receiving loose impression material. This arrangement also forms an improved method of mounting anti-shift inserts.

Abstract: A process for making ductile iron castings and apparatus for practicing the process wherein molten metal is poured through a pressure head into a sealed reaction chamber adapted to contain a nuduralizing agent and then into a reservoir from which the molten metal flows to the casting cavity; the reaction chamber and reservoir are formed in the top surface of a single mold part of a two part mold assembly; the rate of molten metal flowing into the reaction chamber is greater than the rate of molten metal flowing from the reaction chamber and the rate of molten metal flowing into the reservoir is greater than the rate of molten metal flowing from the reservoir to the casting cavity.

Abstract: A mold for casting cylinder blocks of combustion engines in an upright position includes a cope and a barrel core located therewith for defining a cylinder bore. A drag defines a crank space and is configured for cooperating with the cope to define a cylinder block such that the drag and cope can be stripped in an axial direction with respect to the cylinder bore.

Abstract: A permanent casting mold has its casting cavity coated with a sand liner of varying thickness. The liner is thicker where the cast article section is thinner and the liner is thinner where the cast article section is thicker so as to permit the thicker sections to cool faster while the thinner sections cool slower. The different thicknesses of the liner are correlated so that the respective sections of the article are sufficiently cooled at about the same time for removal of the article from the mold. The mold is a cope and drag-type flask mold whose casting cavity halves are oversized relative to the cast article. The sand liner is formed therein by temporarily positioning a pattern within the permanent casting cavity halves and sand filling the space between the pattern and cavity wall. The exterior surface of the pattern corresponds to the cast surface of the article.

Abstract: A process for casting ingot molds wherein a smooth, rigidized insulative board is used to form the as cast bottom surface of the ingot mold to produce a smooth flat surface which does not require machining and to permit slow cooling and solidification so that a uniform macrostructure and microstructure is effected.

Abstract: A high temperature mold assembly particularly adapted for thermit reaction welding, and mold components and mold compositions therefor, based on a mined aggregate containing carbon and silica and thermosetting, non-hygroscopic resinous binder.

Abstract: A thin-walled, resin-bonded sand, shell mold for the vacuum counter-gravity casting of metal comprising cope and drag halves glued together at a parting line therebetween. The drag includes a flange extending beyond the periphery of the cope which flange has an upper sealing surface formed by a drag-shaping pattern for effecting a seal with the mouth of the vacuum chamber used to fill the mold.

Abstract: A horizontal casting technique and mold for use specifically with shell molds and runner feeder sections. The runner feeder sections are assembled within the shell molds such that the ends of the runner feeder section protrude from the mold and can be flow connected to a runner feeder of an adjacent assembly. A plurality of these assemblies constitute the horizontal mold having a horizontal runner feeder and a plurality of shell molds in spaced, side-by-side relationship.

Abstract: A disposable sprue cup for use in a metal casting process using a mold pattern embedded in unbound process sand having a grain size, the disposable sprue cup being made of bonded sand having a grain size substantially equal to the grain size of the process sand and having a binder that breaks down under the heat of resident metal remaining in the cup after the casting process is completed.

Abstract: A cavity in a body of particulate moulding material has at least one rib-like formation for gripping an object received in the cavity. In the case of a metal casting mould a riser sleeve (1) is inserted into a cavity (9) in the top part of the mould and the cavity (9) is produced by means of a tapered former (5) the exterior of which has a plurality of radially spaced apart recesses (6) extending between the top and towards the bottom of the former and which has a negative taper from bottom to top. The depth of the recesses (6) is such that circles geometrically inscribed inside the base of the recesses (6) have diameters smaller than the corresponding mean outside diameters less three times the standard deviation of the riser sleeves (1) to be used. The recesses (6) form ribs (11) from the moulding sand and the ribs (11) grip the outer surface of the sleeve (1).

Abstract: A locating core for sand molds, has a larger diameter frusto-conical upper portion and a smaller diameter frusto-conical lower portion which are joined together at the bases. A mold cope and drag each have two conical depressions therein adapted to receive the upper and lower portions of the locating core respectively and positioned so that the mold cavities in the cope and drag are in proper registration when the depressions are in registration. A step is formed on the core between the diameters of the bases at the junction of the upper and lower cone portions. The step rests on the upper surface of the drag when the core is set in the drag depressions and the cope is then placed so that the cope depressions engage the upper conical portions, whereby the cope and drag mold cavities are in registration.

Abstract: An improved method is utilized to make an improved mold for forming a plurality of small objects, such as piston rings. The mold is made by stacking a plurality of mold sections formed of gas permeable material, such as CO.sub.2 sand, resin bonded sand or green sand. The stacked mold sections are then clamped together to hold them against movement relative to each other. A wet coating of liquid ceramic material is then applied over the stack of mold sections. This liquid ceramic mold material is dried to form a rigid gas permeable ceramic casing which encloses the stack of mold sections. The rigid casing of ceramic material holds the mold sections against movement relative to each other to prevent break-out of metal from between the mold sections when a flow of molten metal is directed into the mold cavities. Due to the gas permeable construction of both the rigid ceramic casing and the mold sections, gas can readily escape from the mold as the molten metal enters the mold cavities.

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 method of casting is provided which uses boxless moulds. The method comprises the steps of stacking a plurality of boxless moulds substantially horizontally on one another in a frame to form a substantially vertical stack, pivoting the frame with the moulds therein through an angle of approximately 90.degree. so that each mould stands substantially vertically, and filling the moulds with molten metal while they are in the substantially vertical position.

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: Moulding apparatus comprises a mould box support structure having spaced support members for receiving and supporting lug members formed at opposite ends of a mould box. The mould box is formed in two separable parts each incorporating at opposite ends thereof a lug member having a substantially semi-circular outside profile so that when the mould box parts are abutted the lug members of one box part register with the lug members of the other box part to provide a substantially circular surface which acts as a bearing for the mould box so that the box can be rotated on the support structure for convenience of handling. In one form the mould box is for use with the V-Process of moulding and suction is applied to the chambers within the walls of the mould box parts via conduits extending through the lug members of respective box parts. In one form the support structure includes a circular table which is indexed so that a mould box is sequentially processed through several processing stations.

Abstract: In making columnar grained castings the shell mold is spaced from the chill plate by a ceramic ring on which the mold is positioned, the ring being made thicker and/or of a different ceramic from the mold to withstand the thermal stress developing while the mold is being heated for pouring, so that the mold, not being subjected to such stresses at the base, may be made thinner for producing better castings. In this way the best mold material for the purpose may be selected, as, for example, a material to have no reaction with the alloy and, by lowering the thermal gradient decrease the likelihood of mold failure.

Abstract: A molding method comprising steps of bringing a shielding mold member into contact with the shaping surface of a shaping mold member to provide a mold assembly, filling a charge of a heat resisting particulate material in space disposed opposite the shaping mold member with respect to the shielding mold member, rendering negative the internal pressure of the space containing the charge so as to draw the shielding mold member toward the charge and cause the same to adhere thereto, removing the shaping mold member from the mold assembly so as to form a cavity defined by the shielding mold member, and pouring a molten metal into said cavity.