Abstract: A heating machine for heating an ingot of a metal such as a magnesium alloy. The heating machine has a heating chamber equipped with a RF induction coil capable of swinging about a horizontally axis. The coil is placed horizontally, and the metal ingot is fed into the coil from an introduction chamber by a pushrod. Stoppers prevent the ingot from falling from the RF induction coil when it is switched from its horizontal posture to its vertical posture. The coil is wound on a cylindrical member. A rotatable hollow shaft is firmly mounted to the holder in a perpendicular relation to a substantially axially central portion of the cylindrical member. A part of the coil is inserted in the hollow shaft via an insulating material. The rotatable hollow shaft is swung by a swinging mechanism. The induction heating coil is wound on a ceramic holder. A metal ingot is inserted in the holder with a given clearance.

Abstract: A system and method of electroslag refining of metal is taught. The system and method includes the introduction of unrefined metal into an electroslag refining process in which the unrefined metal is first melted at the upper surface of the refining slag. The molten metal is refined as it passes through the molten slag. The refined metal is collected in a cold hearth apparatus having a skull of refined metal formed on the surface of the cold hearth for protecting the cold hearth from the leaching action of the refined molten metal. A cold finger bottom pour spout is formed at the bottom of the cold hearth to permit dispensing of molten refined metal from the cold hearth. The dimensions of the cold finger apparatus pour spout are controlled by positioning a retaining means around the outer surface of the pour spout thereby controlling the flow rate of molten metal through the cold finger apparatus.

Abstract: A device for preheating a metal casting channel (3). The device is positioned in a rapidly removable manner by a frame (1) consisting of a stationary portion (12) and a movable portion (26). The channel (3) comprises a refractory part (5) surrounded by an insulating coating (7), an inductor (8) and refractory concrete (10) within a shell (11). The preheating device includes the inductor (8) and an element (2) made of a refractory and electrically conductive material. Said device is useful for evenly and uniformly preheating a metal casting channel (3).

Abstract: A levitation melting method and device through which a material having various configurations can be melted through efficient induction heating. First, a starting material(WB), whose outer diameter has been adapted to the inner diameter of a crucible(13), is inserted in crucible(13). The crucible(13) is shielded with argon gas, thereby starting the melting of the material(WB) to molten metal(WM). Subsequently, a suction tube(33) of a mold(31) is inserted into the molten metal(WM) for drawing a part of molten metal(WM) up into the mold(31) for casting. After part of the molten metal(WM) is drawn up, a sliding cover(15) is slid such that a material holder(19) is positioned right above the crucible(13). By opening a sliding plate(35) of the material holder(19), material pieces(WS) are inserted from the material holder(19) into the molten metal(WM) left in the crucible(13).

Abstract: Molten metal melted in a levitation melting furnace is cast through a suction pipe immersed therein from above into a mold having a gas permeability in a double-structure mold chamber arranged directly above the melting furnace. The metal is levitation-melted in an inert atmosphere under atmospheric pressure. An outer mold chamber of the double-structure mold chamber is joined to the levitation melting furnace. Pressure in the outer mold chamber and in an inner mold chamber of the double-structure mold chamber and in an upper space in the levitation melting furnace is reduced to below atmospheric pressure. The suction pipe arranged in the inner mold chamber and communicating with the mold therein is immersed into the molten metal. The molten metal is cast into the mold under an increased pressure by blowing an inert gas into the upper space in the melting furnace. The inner mold chamber is raised, thereby pulling out the suction pipe from the molten metal.

Abstract: Apparatus for heating and pouring metal and metal alloys. A metal melting and pouring apparatus suitable for graining the molten material is described. A graphite crucible having at least one exit orifice in its lower, tapered portion, a graphite barrier plate or disk having a plurality of orifices located within the crucible on the tapered portion thereof, and an element for heating the apparatus to temperatures sufficient to melt the metal, have been found to produce a steady stream of consistent droplet-size molten metal, while maintaining a choosen level of liquid metal in the crucible to prevent less dense impurity materials from passing through the exit orifice(s) of the crucible, and to improve the efficiency of melting additional metal subsequently introduced into the crucible.

Abstract: A die casting method and a die casting machine of the invention is provided. The method comprises the steps of forming a casting sleeve comprising an inner cylinder and an outer cylinder, having a conductor material, and disposing an induction coil on the outer periphery of the outer cylinder. The conductor material may be in the form of a plurality of conductors uncontinuously disposed about the cylinder or it may be in the form of a single conducting material having a plurality of slits. A material to be cast in the casting sleeve may be heated, maintained a constant temperature and stirred by electromagnetic induction. The material may be substantially separated from the wall face of the casting sleeve by an electromagnetic force generated between the conductor and the material and the temperature drop of the material may be suppressed.

Abstract: A decomposable casting core (56a, 56b) is formed in-situ with a sleeve-like liner member (64) and the assembly mounted within the mold cavity (24) of a cylinder block casting mold (22) for lining piston cylinder chambers (62a, 62b) of a cylinder block (26) cast within the mold (22). The liner member (64) is formed with an inner annular recess (80) which receives a corresponding annular projection (76) of the core (56a, 56b) for preventing the liner (64) from sliding axially on the core (56a, 56b) during casting.

Abstract: An ingot having a predetermined amount of electrolytic copper and a small percentage of boron copper alloy is rapidly heated to about 2,100.degree. F. in a clay graphite crucible by induction coils surrounding the crucible. The crucible and the entire amount of molten copper are automatically transferred to a cavity defined within a shot cylinder above a vertically movable shot piston of a vertical die casting press. A shuttle moves a lower end ring mold and a stack of connected rotor laminations into a position above the shot cylinder, and the press moves an upper end ring mold downwardly to clamp the stack between the molds and against the cylinder. The molten copper is rapidly injected upwardly through gates within the lower mold and into end ring cavities within the molds and also through connecting aligned bar slots within the stack of laminations with a shot pressure of about 2250 psi.

Abstract: The apparatus includes casting stations disposed around a melt chamber of a furnace. Each casting station has a tundish for selectively transporting melt to the desired casting station. The apparatus is provided with apertures in the walls of the melting chamber to allow the tundishes to enter the melt chamber through fixed vacuum seals to receive molten metal from a tiltable melting unit and to convey the melt through the vacuum gate valve to the desired casting station.

Abstract: Apparatus for inductively melting a quantity of metal without a container includes a first induction coil having a plurality of turns defining a volume for receiving a quantity of metal, the first induction coil being adapted to exert a force on the metal, a second induction coil having a plurality of turns at substantially right angles to the turns of the first induction coil, the second induction coil, being disposed within said volume coaxial with the first induction coil. Both the first and second induction coils have connectors thereon for connecting the coils to at least one power supply for energizing the first and second induction coils. A support is provided for supporting the metal from below, and has an opening through it. The support includes a raised segmented rim around substantially its entire periphery. The support is maintained at a preselected temperature. In an alternate embodiment, structure is also provided for imparting rotational motion to the support.

Abstract: Precision casting of titanium or titanium alloy includes establishing molten metal by induction heating in an assembly formed with water cooled copper segments disposed circlewise on the inside of an induction coil in a state insulated from each other and casting the molten metal into a permeable mold by vacuum casting. The precision casting method uses apparatus including an induction coil, an assembly formed with the aforementioned copper segments, an arrangement for feeding a base metal from the under side thereof and a permeable mold into which the molten base metal in the assembly is transferred by vacuum casting. It is possible to obtain precision castings of metal having high melting points and high actvitiy such as titanium, titanium alloy or the like.

Abstract: A permanent mold for mold-casting reactive metals and metal alloys (FIG. 1) includes a multiple of radially disposed, plate-like segments 3, 3', 3", . . . which enclose the workpiece 12 and are preferably made of cooled metallic material and which form together the permanent mold including a top inlet opening 14 and a bottom opening 15 for withdrawing the working piece; in order to close the withdrawal opening 15, a closing plate 9 is provided which is composed of a multiple of ring segments 13, 13', 13", . . . and the permanent mold 5 is enclosed by a magnetic coil 6 so as to generate an electromagnetic field.

Abstract: The solid metal to be melted is placed on a support, within an induction coil which is adapted to provide a greater electromagnetic force towards the lower portion of the quantity of metal. When energy is provided to the coil, the metal melts from the top downward, but the concentration of electromagnetic force towards the bottom of the metal causes the liquid metal to retain a cylindrical shape. When most of the metal is melted, the liquid metal passes through an opening in the support. In a preferred embodiment, the coil is movable relative to the quantity of metal, and at the beginning of the melting process only the top portion of the quantity of metal is disposed within the coil. As the quantity of metal melts, the coil is moved downward. The method may also be used for removing impurities from the quantity of metal.

Abstract: The solid metal to be melted is placed within an induction coil which is adapted to provide a greater electomagnetic force towards the lower portion of the quantity of metal. The solid metal rests on a support, having an opening therethrough, which is kept at a low temperature relative to the metal as it melts. When energy is provided to the coil, the metal melts from the top downward, but the concentration of electromagnetic force towards the bottom of the metal causes the liquid metal to retain a cylindrical shape. When most of the metal is melted, the liquid metal passes through the opening in the support into a casting mold.

Abstract: Intercell fusing apparatus for use in a battery having flat tombstone type connections, each tombstone having a pair of vertically and horizontally outwardly extending portions of fusible material closely surrounding a vertical partition of electrically insulating material having a hole extending horizontally therethrough. It comprises a mold closely surrounding each pair of vertical portions of the tombstones and surrounding a partition portion above the hole, and a pair of interconnected coils preferably having double windings on each side of the partition to effect fusion of the tombstones within the mold when energized by a source of high frequency alternating current.

Abstract: Apparatus and method for providing a constant level of molten metal to a mold in gas permeable shell mold casting. The apparatus includes a furnace for melting and Holding metal to be cast. Structure is provided for locating a mold to be filled in casting relationship with the molten metal in the furnace and for causing molten metal to be drawn from the furnace into the mold. Structure responsive to the sensor is provided for tilting the furnace relative to the mold causing the level of the molten metal to remain constant relative to the mold as the mold is being filled.

Abstract: Apparatus for heating intermediate ladles or tundishes, for example, in continuous casting processes. The apparatus comprises at least one coil having an iron core, which is disposed adjacent the ladle or tundish. The ladle or tundish and the coils are arranged so as to be movable with respect to each other. The ladle or tundish is adapted to be placed in a heating position adjacent to the coil, which is thus closely connected with the bottom or lower parts or corners of the ladle or tundish, in order primarily to heat the lowermost parts of the melt stored in the tundish.

Abstract: A furnace assembly for casting directionally solidified articles, such as turbine blades. A pair of tunnels feed blanket insulative material towards the bottom of the heating chamber to engulf the mold as it exits the chamber atop a water cooled pull rod.

Abstract: A casting apparatus comprising a member defining a molding space, and at least one conductor for electromagnetic induction heating mounted on the member at positions away from the molding space, the conductor being electrified to generate electromagnetic induction heat for a molten metal poured into the molding space.

Abstract: An arrangement for controlling the pouring of a melt out of a crucible with a hole in the bottom which hole is blocked while the material is being melted with a closure plate that melts through locally as the result of heat transferred from the melt. To precisely establish the time at which the closure plate melts through, the plate is cooled from below while the starting material is being melted. Cooling is at least decreased and preferably terminated when it is time to pour out the melt. The plate can be cooled by a flow of a gas coolant directed against it or by contact with a cooling element that is raised into position against it from below.

Abstract: A mold for use in an apparatus and process utilizing an electromagnetic field to stir a molten metal or metal alloy comprises a plurality of laminations of thermally and electrically conductive material separated by electrically insulating material. The electrically insulating material is oriented to minimize at least some of the flow path lengths of currents induced in the mold whereby magnetic induction loses caused by the mold are substantially reduced and the stirring efficiency is enhanced.

Abstract: Apparatus for casting directionally solidified articles is disclosed. Concepts for obtaining a desired temperature profile in an induction furnace are discussed.An induction furnace 10 has increased heating capacity at the withdrawal end 32 of the susceptor 28. A hot zone baffle 42 is disposed at the withdrawal end to inhibit the radiation of heat energy from the hot zone 12. A plurality of grooves 34 are formed about the interior of the susceptor at the withdrawal end to inhibit the conduction of heat energy out of the susceptor. A preferred thermal profile in the operating furnace with a peak temperature in close proximity to the withdrawal end results.

Abstract: A diecasting apparatus according to the invention comprises an injection cylinder vertically arranged having its upper end communicating with a cavity of dies for diecasting, a melt chamber cylinder coaxially located below the injection cylinder and having an inner diameter substantially the same as that of the injection cylinder, a plunger movable through the melt chamber and injection cylinders to form a melt chamber defined by an upper surface of the plunger and an inner surface of the melt chamber cylinder, thereby to form a hermetically closed space by the melt chamber and cavity, and heating and melting means arranged about the melt chamber cylinder, thereby enabling the molten material to be injected into the cavity through the shortest distance for the shortest period of time, whereby high quality diecast products of high melting point metals are obtained.

Abstract: Disclosed is a mold structure for casting large metallic parts such as ingots so as to avoid the formation of the "shrinkage pipe" which normally develops on the exposed top surface of such castings during their solidification. The structure comprises a cap for placement on a mold which includes a diaphragm having a front surface located to intercept radiation emitted from the top surface of the cooling metal mass and to reemit radiation back thereto, and a means for returning radiation emitted from the back surface of the diaphragm such as an infrared reflector or a stack of baffles. The cap may include means for cooling the reflective surface and suitable ports which allow the interior of the mold and cap to be evacuated. Portions of the mold adjacent its open top may be provided with insulation to prevent heat loss from the metal by conduction. Various means for providing make-up heat to the top surface of the metal mass may also be included in the structure.