Abstract: A process for the casting of metals and their alloys includes the steps of providing at least a mold equipped with a plurality of cooling nozzles, making a layer of coolant permeable materials covering the nozzles and maintaining the materials at desired temperatures, delivering a molten metal into the mold, supplying predetermined amount of coolant to each nozzles to contact the casting at desired rate, time, and duration to achieve an acceptable level of progressive solidification from the distal end of the casting towards the riser until the casting has reached desired temperatures.

Abstract: Disclosed is a method and system for adjusting process parameters of a die-casting machine, and a storage medium. The method and the system can receive die wheel type, molten aluminum temperature, interruption time and defect information in real time, respond to the above information one by one according to a set response priority order, select die-casting process parameters, and automatically adjust different process parameters for different products and different working conditions, thereby realizing simultaneous control of multiple die-casting machines, replacing manual adjustment and improving product quality stability and production efficiency.

Abstract: A casting mold (260) comprises a shell (262) extending from a lower end (264) to an upper end (266) and having: an interior space (280) for casting metal; and an opening (268) for receiving metal to be cast. A plurality of thermocouples (900) are vertically-spaced from each other on the shell.

Abstract: A method for controlling a casting plant has at least one mould for receiving a fluid material, the fluid material solidifying in the mould during a solidifying time, at least one process parameter being detected during the production process and the solidifying time being determined in accordance with the process parameter detected.

Abstract: A casting method and apparatus are provided for casting a near-net shape article, such as for example a gas turbine engine blade or vane having a variable cross-section along its length. A molten metallic melt is provided in a heated mold having an article-shaped mold cavity with a shape corresponding to that of the article to be cast. The melt-containing mold and mold heating furnace are relatively moved to withdraw the melt-containing mold from the furnace through an active cooling zone where cooling gas is directed against the exterior of the mold to actively extract heat. At least one of the mold withdrawal rate, the cooling gas mass flow rate, and mold temperature are adjusted at the active cooling zone as the melt-containing mold is withdrawn through the active cooling zone to produce an equiaxed grain microstructure along at least a part of the length of the article.

Abstract: An improved and efficient method and apparatus for convective cooling of cast sand molds containing molten metal, utilizing vertically-arrayed cooling stations (preferably arranged on a plurality of shelves inside a housing enclosure for temporarily storing said sand molds during their cooling from a molten temperature level to a lower solidification temperature. A draft of cooling air is circulated through said stations in said housing whereby the time for solidifying the molten metal in said cast sand molds is reduced as compared with passive air cooling of said molds. Robot means are provided for moving hot sand molds from a feeding port in said housing to said shelves and for moving cooled sand molds from said shelves to a delivery port in said housing.

Abstract: A method for monitoring and/or controlling a die casting operation using the rate of coolant flow through cooling lines of a die and the amount of heat being removed from the die by the cooling lines.

Abstract: A die cooling system for cooling a cast wheel for an automotive vehicle is provided that includes a die, multiple thermocouples embedded in the die, which measure the actual cast metal temperature, adjustable cooling valves, and a control system. The control system receives actual casting metal temperature data from each thermocouple to control the operation of the adjustable cooling valves.

Abstract: A method for monitoring and/or controlling a die casting operation using the rate of coolant flow through cooling lines of a die and the amount of heat being removed from the die by the cooling lines.

Abstract: A mold temperature control system comprises a mold section having a cavity, a fluid circuit to distribute a flow of a conditioning fluid, the fluid circuit being positioned spaced apart from the cavity, a temperature sensor positioned in the mold to generate a signal representative of a temperature in the mold, a controllable supply of the conditioning fluid, and a controller for automatically initiating flow of the conditioning fluid through the fluid circuit in response to an initiation temperature and for automatically terminating flow of the conditioning fluid through the fluid circuit in response to a termination temperature.

Abstract: An investment casting process utilizes rapid cooling during solidification to achieve a desired final microstructure. A molten high temperature aluminum alloy is poured into a ceramic shell mold. The ceramic shell mold is then lowered into an oil bath held in a quenching tank to rapidly cool the molten material. Thus, solidification takes place quickly via rapid extraction of the latent heat of the metal by the quenching oil bath. The rapid solidification achieves a uniform fine microstructure in an as-cast component.

Abstract: A method for process monitoring during die casting or vacuum thixoforming of metals in a mold, wherein the time lapse of temperature (T) is continuously measured on at least one point of the system and the temperature progression of the system is calculated in real time using a program. The time lapse of the heat flow (W) is calculated from the temperature progression of the system and the time lapse of the energy (U) of the system and the solidification heat portion (UE) of the metal solidified in the mold are calculated from the heat flow. At a given time, the calculated values are used as monitoring parameters.

Abstract: Disclosed is a method for increasing production efficiency of mold lines where molten metal or other material requiring a cooling period is poured sequentially into moving molds. The invention particularly comprehends the tracking of individual molds and the individualized control of the cooling time of the molds from beginning to end of the line in the presence of random line stoppages and variant mold size.

Abstract: A method of controlling a solidification rate of a molten liquid material within a casting chamber to form a solid structure upon controlled cooling thereof. The method includes provision of a stationary mold casting chamber having a plurality of sites with respective surface-temperature or heat flux sensors for determining respective site temperatures or heat withdrawal, and with respective independently operable temperature controllers for regulating each respective site temperature. A data base driven microprocessor receives sensor data and selectively and independently operates each controller in accord with algorithmic commands relative a cooling, and thus solidification, rate for the molten material.

Abstract: In producing thin slabs by continuous casting, a method is developed in which internal defects are reduced to improve a production yield. Narrow sides of cast slabs are cooled in a controlled manner to produce cast slabs having a projection in a center of each of the narrow sides to a height of 5-10 mm above the level of the edge portions, and squeeze reduction with a reduction of 10-45% is carried out while an unsolidified portion of the narrow sides of the slab is within 50-80% of the thickness of the cast slab.

Abstract: The shot sleeve of the invention is used in a die casting machine and defines a bore for containing molten metal to be injected into a die. At least one passageway disposed generally parallel to the bore for containing a first fluid having a fluid temperature and a fluid flow rate is provided, whereby substantially uniform temperatures can be maintained across the width of the shot sleeve by controlling the fluid temperature of the fluid flow rate or both the fluid temperature and the fluid flow rate. A die casting machine and an associated method are also disclosed.

Abstract: In a process for centrifugal casting metal pipe in a metal mold in which the mold is cooled by the application of cooling water to the external surface, the application of cooling water is interrupted for a time just prior to the pouring of molten metal to a time generally corresponding to the time of separation of the pipe being cast from the inner surface of the mold to thereby permit limited dilation of the mold and reduce tensile stress in the external portion of the mold.

Abstract: The temperature of a casting die is controlled in a low-pressure casting process for pressurizing the surface of molten metal stored in a closed container to fill the molten metal in a die cavity defined in the casting die. The temperature of the casting die is detected by a temperature sensor, and compared with a preset reference die temperature range. The amount of cooling water to be supplied to the casting die is controlled based on the result of the comparison. When the detected temperature of the casting die falls in the preset reference die temperature range, the molten metal starts to be filled in the die cavity.

Abstract: A mold casting process comprises, after pouring of a molten metal into a mold, rapidly cooling that surface layer of a cast product which is in contact with a mold, and releasing the resulting product from the mold when the surface layer thereof has been converted into a shell-like solidified layer. Such process is used for casting a mechanical part blank and apparatus for carrying out the process is provided.

Abstract: Sand molds stored in a prepour storage system are retrieved and conveyed to a pouring station with a total mold cavity capacity equal to the amount of molten metal to be poured. Despite the fact that the mold cavities vary in size they are delivered to the pouring station in a sequence that accomodates delivery of the molds having variable metal capacity to one of a plurality of cooling conveyor lines so that each cooling line conveys molds which require variable lengths of time to cool before such molds can be conveyed into a punchout where the cope flask is stripped and the sand mass and castings are pushed up from the drag flask and onto a shakeout which conveys sand to a reclaim system and castings to a processing area where the castings are shot blasted, gates and risers are removed, the castings are inspected, flame washed, welded (as needed), ground, chipped, heat treated and then blast cleaned a second time before final grinding, chipping, gauging, final inspection, assembly and storage.

Abstract: Method of and apparatus for casting under pressure light metal alloys in which, under the action of a pressure difference, the molten metal from a furnace, disposed in a hermetically sealed chamber, is displaced via a feed tube for molten metal and fills the cavity of a casting mold, disposed in another hermetically sealed chamber, wherein before the filling of the cavity of the casting mold with molten metal, the latter is subjected to a temperature and a metallurgical pretreatment in two furnaces, which are then in succession brought in position of casting and, at the same time or later, the casting mold is brought to desired temperature parameters, the process of casting is performed, the cast body is removed from the casting mold and the cycle is repeated. The temperature of the casting mold, before and after its filling with molten metal, is regulated by controlling the powers of the cooling and the heating systems arranged within the casting mold.

Abstract: A method of die casting using a plunger tip of a reciprocal plunger for forcibly injecting the molten metal supplied to the inner space of a sleeve into the mold cavity through a spool bush connected therebetween. The temperature of at least a portion of at least one of the plunger tip, the sleeve, and the spool bush is measured. Retracting of the plunger is commenced on the basis of the measured temperature after each shot of die casting. The measured temperatures of the plunger tip, the sleeve, and/or the spool bush is utilized for calculating the clearance at the peripheral surface of the plunger tip, and the retracting of the plunger is commenced at the time the clearance is calculated to reach a predetermined set value of clearance.

Abstract: Magnesium and magnesium alloy castings are produced using porous, calcined plaster of Paris molds by filling the mold cavity and the pores communicating therewith with a pressurized inhibitor gas comprising sulfur hexafluoride and monitoring temperature conditions during cooling of the cast metal using a thermocouple placed in the mold close to the sprue whereby, in the event of an exotherm as indicated by non-decreasing temperature, the mold may be broken to prevent an explosion.

Abstract: A die casting system comprises a machine of the balanced, dual movement type wherein the part is cast and trimmed without any lateral movement. Both halves of the molds or dies are moved equal distances to and from the part plane. The machine incorporates a system of metal injection on the mold parting line with a runner-drain provision; provision for supporting the part at a plurality of points after the die opening; hydraulic fluid volumetric flow reduction; various nozzle configuration options and a heat transfer system for the dies. In addition, a part trimming machine is disclosed together with a cable transfer for moving the part from the casting machine to the trimming machine.

Abstract: A die casting system comprises a machine of the balanced, dual movement type wherein the part is cast and trimmed without any lateral movement. Both halves of the molds or dies are moved equal distances to and from the part plane. The machine incorporates a system of metal injection on the mold parting line with a runner-drain provision; provision for supporting the part at a plurality of points after the die opening; hydraulic fluid volumetric flow reduction; various nozzle configuration options and a heat transfer system for the dies. In addition, a part trimming machine is disclosed together with a cable transfer for moving the part from the casting machine to the trimming machine.