Utilizing Particular Mold Materials Patents (Class 164/520)
  • Patent number: 11261515
    Abstract: It is an object to provide a method for producing a member for a molten metal bath which is less likely to form minute cracks and pores in a pores-sealing coating film, and to provide a method for producing a member for a molten metal bath which can restrain adhesion of an alloy such as dross. The method for producing a member for a molten metal bath is characterized by applying or spraying, to a cermet thermal spray coating film formed on a base material or an oxide-based ceramic thermal spray coating film formed on a base material, a mixed solution obtained by adding aluminum dihydrogen phosphate and inorganic particles having a layered hexagonal crystal structure to a silica sol solution as a solution for sealing pores of the thermal spray coating film, and firing the mixed solution which is applied or sprayed to the thermal spray coating film.
    Type: Grant
    Filed: July 19, 2018
    Date of Patent: March 1, 2022
    Assignee: NIPPON STEEL & SUMIKIN HARDFACING CO., LTD.
    Inventor: Yu Li
  • Patent number: 9174270
    Abstract: The mold set is constructed with a cope, a drag, cheeks, and a core. In a case where the mold set is closed before molten metal is fed, a first clearance between a first mold (cope) that is located above a casting shape forming part of the core and the casting shape forming part is smaller than a second clearance between an upper surface of a core print of the core and a second mold (cheek) that is opposed to the upper surface.
    Type: Grant
    Filed: April 13, 2012
    Date of Patent: November 3, 2015
    Assignee: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventor: Norimitsu Aoki
  • Publication number: 20150096713
    Abstract: A method of fabricating a die cast article is disclosed and includes forming an insert with an additive manufacturing process to define a cavity for generating desired part geometry. The insert is then mounted within a mold tool, material is injected into the cavity to fill the cavity and form a cast article.
    Type: Application
    Filed: September 30, 2014
    Publication date: April 9, 2015
    Inventor: John Joseph Marcin
  • Publication number: 20150027658
    Abstract: A hybrid ceramic/sand casting method of manufacturing a metal part. The method is especially suitable for manufacturing engine cylinder blocks or cylinder head, which have very small internal passages or other very small internal features. These parts are formed using a hybrid core having at least one ceramic section and at least one sand section, with the ceramic section being used to create the internal feature. A mold cavity is created for the part, and the hybrid core is positioned in the mold. Molten metal is introduced into the mold, and after the metal cools, the core is removed, thereby forming the part with the internal feature.
    Type: Application
    Filed: July 23, 2013
    Publication date: January 29, 2015
    Applicant: Southwest Research Institute
    Inventors: Barry E. Westmoreland, Douglas A. McKee, Marc C. Megel, Mark A. Tussing, Thomas E. Reinhart, David P. Branyon
  • Publication number: 20150013934
    Abstract: An article includes a first portion having a first grain pattern and a second portion having a second grain pattern different from the first grain pattern. The article is a cast article such as a turbine engine blade.
    Type: Application
    Filed: September 29, 2014
    Publication date: January 15, 2015
    Inventor: Mark White
  • Publication number: 20150016944
    Abstract: A gas turbine component having a cooling passage is disclosed. In one form, the passage is oriented as a turned passage capable of reversing direction of flow, such as a turned cooling hole. The gas turbine engine component can include a layered structure having cooling flow throughout a region of the component. The cooling hole can be in communication with a space in the layered structure. The gas turbine engine component can be a cast article where a mold can be constructed to produce the cooling hole having a turn.
    Type: Application
    Filed: December 27, 2013
    Publication date: January 15, 2015
    Inventors: Peter L. Vandervaart, Jeffrey F. Rhodes, Okey Kwon, Tab M. Heffernan
  • Patent number: 8932518
    Abstract: The disclosure relates generally to mold compositions and methods of molding and the articles so molded. More specifically, the disclosure relates to mold compositions, intrinsic facecoat compositions, and methods for casting titanium-containing articles, and the titanium-containing articles so molded.
    Type: Grant
    Filed: February 29, 2012
    Date of Patent: January 13, 2015
    Assignee: General Electric Company
    Inventors: Bernard Patrick Bewlay, Stephen Bancheri, Michael Weimer, Joan McKiever, Brian Ellis
  • Publication number: 20140348693
    Abstract: A casting system for molding metal. The casting system has a mold comprising a cavity in a predefined shape. A riser in flow communication with the mold wherein the riser provides molten metal to said cavity as the molten metal freezes. A riser breaker insert is between the mold and the riser wherein the riser breaker insert comprises voids. A molten metal supply is provided which is capable of filling the mold and the voids of said riser breaker insert and at least partially filling the riser.
    Type: Application
    Filed: May 16, 2014
    Publication date: November 27, 2014
    Applicant: Porvair PLC
    Inventors: Donald B. Craig, Christopher J. Mann, David P. Haack, James R. Schmahl
  • Patent number: 8833434
    Abstract: A method for making hollow metal tubes includes a step combining a polyphenylene sulfide-containing resin with a water soluble carrier resin to form a resinous mixture. The resinous mixture is then extruded to form an extruded resinous mixture. The extruded resinous mixture includes polyphenylene sulfide-containing fibers within the carrier resin. The extruded resinous mixture is contacted (i.e., washed) with water to separate the polyphenylene sulfide-containing fibers from the carrier resin. The polyphenylene sulfide-containing fibers are then coated with a metal layer. The hollow metal tubes are then formed by removing the polyphenylene sulfide-containing fibers.
    Type: Grant
    Filed: June 8, 2012
    Date of Patent: September 16, 2014
    Assignee: GM Global Technology Operations LLC
    Inventors: James Mitchell, Timothy J. Fuller, Lijun Zou
  • Publication number: 20140182808
    Abstract: A method of manufacturing a porous metal foam having pores of nano size includes: manufacturing a porous polymer foam containing pores of nano size; and coating metal on the porous polymer foam through electroless plating. The present invention provides porous metal foams which contains nano-sized pores and hence, their specific surface area is maximized owing to the regularly-patterned nanoporous structure formed inside.
    Type: Application
    Filed: December 31, 2012
    Publication date: July 3, 2014
    Applicant: Kookmin University lndustry Academy Cooperation Foundation
    Inventors: Myoung-Geun CHOI, Hyun-Gyung JO, Hye-Ji PARK, Yoon-Sook NOH, Yun-Sung KIM, Chang-Ui AHN, Seok-Woo JEON, Dong-Seok KIM, Do-Kyung KIM, Hee-Man CHOE
  • Patent number: 8662146
    Abstract: The present invention provides a structure for casting containing an organic fiber, an inorganic fiber, inorganic particles (A) having an average particle diameter of 50 to 150 ?m, and a binder (a), having a surface layer containing refractory inorganic particles (B) having an average particle diameter of 1 to 100 ?m selected from metal oxides and metal silicates, a clay mineral, and a binder (b), on the surface of the structure.
    Type: Grant
    Filed: June 24, 2011
    Date of Patent: March 4, 2014
    Assignee: Kao Corporation
    Inventor: Haruki Ikenaga
  • Publication number: 20130327494
    Abstract: A method for making hollow metal tubes includes a step combining a polyphenylene sulfide-containing resin with a water soluble carrier resin to form a resinous mixture. The resinous mixture is then extruded to form an extruded resinous mixture. The extruded resinous mixture includes polyphenylene sulfide-containing fibers within the carrier resin. The extruded resinous mixture is contacted (i.e., washed) with water to separate the polyphenylene sulfide-containing fibers from the carrier resin. The polyphenylene sulfide-containing fibers are then coated with a metal layer. The hollow metal tubes are then formed by removing the polyphenylene sulfide-containing fibers.
    Type: Application
    Filed: June 8, 2012
    Publication date: December 12, 2013
    Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC
    Inventors: James Mitchell, Timothy J. Fuller, Lijun Zou
  • Patent number: 8569425
    Abstract: The present invention relates to modified phenolic resins which contain silicic acid ester units. The modified phenolic resins may, for example, be used as components of a foundry binder system. The invention also relates to a method for producing such modified phenolic resins and to two-component binder systems which contain these modified phenolic resins. The invention furthermore relates to methods for producing foundry molds and foundry cores which contain the modified phenolic resins, and to the foundry molds and foundry cores themselves.
    Type: Grant
    Filed: June 21, 2011
    Date of Patent: October 29, 2013
    Assignee: Huttenes-Albertus Chemische Werke GmbH
    Inventors: David Strunk, Gerard Ladegourdie, Frank Lenzen
  • Patent number: 8563662
    Abstract: The present invention relates to modified phenolic resins which contain silicic acid ester units. The modified phenolic resins may, for example, be used as components of a foundry binder system. The invention also relates to a method for producing such modified phenolic resins and to two-component binder systems which contain these modified phenolic resins. The invention furthermore relates to methods for producing foundry molds and foundry cores which contain the modified phenolic resins, and to the foundry molds and foundry cores themselves.
    Type: Grant
    Filed: August 19, 2009
    Date of Patent: October 22, 2013
    Assignee: Huttenes-Albertus Chemische Werke GmbH
    Inventors: David Strunk, Gerard Ladegourdie, Frank Lenzen
  • Patent number: 8555950
    Abstract: Heat flow and mechanical strength of an engine component are improved by an organic-like casting core. Hardened granules are formed of a core material having a three-dimensional solid shape. A secondary binder is applied to the hardened granules. A multiplicity of the granules are agglomerated in a master mold in a shape of a water jacket of the engine component, and the secondary binder is hardened to form an organic-like core having a continuous web structure. A plurality of other cores are formed in respective master molds to define respective surfaces of the engine component. The organic-like core is assembled with the other cores to form a casting mold. The engine component is cast by flowing molten metal into the casting mold, thereby forming a continuous parent metal bridging the water jacket having a predetermined porosity. The core material is removed from the engine component after casting.
    Type: Grant
    Filed: October 25, 2011
    Date of Patent: October 15, 2013
    Assignee: Ford Global Technologies, LLC
    Inventor: Charles Fabros
  • Patent number: 8528626
    Abstract: The present inventions provide a method for forming molds and a core which generates no gases with bad effects on the human bodies while the binders are heated. In particular, the present inventions provide a method for forming molds and a core comprising an aggregate material mixture consisting of granular aggregate materials, wherein the aqueous binders and water are foamed with stirring, filled into a space for forming molds, and caked with an evaporating water component. In an embodiment, molds can be further cured by adding cross linking agents before and after they are taken out from the space for forming. Further, an aggregate material mixture for forming molds used for the method for forming molds of the present inventions is provided.
    Type: Grant
    Filed: November 2, 2011
    Date of Patent: September 10, 2013
    Assignee: Sintokogio, Ltd.
    Inventors: Toshihiko Zenpo, Yusuke Kato, Norihiro Asano, Masahiko Nagasaka, Kazuyuki Nishikawa
  • Publication number: 20130220573
    Abstract: A mold core package for forming a molding tool includes a plurality of stacked particulate layers having a binding agent. The plurality of stacked particulate layers form sacrificial walls defining a mold cavity. A sacrificial displacement line and a sacrificial displacement body extend from the mold core package and are adapted to displace a molten material applied to the mold core package.
    Type: Application
    Filed: February 29, 2012
    Publication date: August 29, 2013
    Applicant: Ford Motor Company
    Inventors: Charles Alan Rocco, Jeffery N. Conley, Raymond Edward Kalisz, Bernie Gerard Marchetti, Larry Edward Ellis, Harold P. Sears, James Todd Kloeb, Alan Lawrence Jacobson, Ronald Hasenbusch
  • Publication number: 20130224066
    Abstract: The disclosure relates generally to mold compositions and methods of molding and the articles so molded. More specifically, the disclosure relates to mold compositions, intrinsic facecoat compositions, and methods for casting titanium-containing articles, and the titanium-containing articles so molded.
    Type: Application
    Filed: February 29, 2012
    Publication date: August 29, 2013
    Applicant: GENERAL ELECTRIC COMPANY
    Inventors: Bernard Patrick BEWLAY, Stephen BANCHERI, Michael WEIMER, Joan McKIEVER, Brian ELLIS
  • Publication number: 20130220572
    Abstract: A molding assembly for making molded parts includes a molding tool having conformal fluid lines that follow contours of a molding surface of the molding tool. The conformal fluid lines are defined in the molding tool during casting by sacrificial displacement lines formed by a three-dimensional printer. A temperature control station is coupled to the molding tool and includes a heating and cooling fluid. A valve station regulates fluid flow to the molding tool.
    Type: Application
    Filed: February 29, 2012
    Publication date: August 29, 2013
    Applicant: Ford Motor Company
    Inventors: Charles Alan Rocco, Raymond Edward Kalisz, Jeffery N. Conley, Bernie Gerard Marchetti
  • Publication number: 20130199749
    Abstract: A method for manufacturing a monolithic hollow body by means of a casting or injection moulding process, the manufacturing method contemplating the steps of: producing at least one lost ceramic core that reproduces the shape of at least one internal cavity of the hollow body, introducing the ceramic core inside a first mould that reproduces in negative the external shape of the hollow body, feeding a molten material inside the first mould by means of a casting or injection moulding process, letting the material inside the first mould solidify, extracting the hollow body from the first mould, and destroying and removing the ceramic core located inside the hollow body.
    Type: Application
    Filed: November 16, 2010
    Publication date: August 8, 2013
    Applicant: FRENI BREMBO S.p.A.
    Inventors: Renzo Moschini, Anna Lisa Calzolaro
  • Publication number: 20130186589
    Abstract: An object is to provide a mold molding method which can provide a high general-purpose property and can reduce a usage quantity of molding sand. In a method for molding a mold (sand mold) by self-hardening molding sand using a caking additive, the mold is molded by disposing hollow spheres each formed to have no clearance therein among molding sand mixed with the caking additive. Preferably, the hollow sphere may be formed by working two metal plates to semispherical shapes and then connecting the semispherical-shaped metal plates to each other by welding their respective whole peripheries. A specific gravity of the hollow sphere may be 0.5 to 2.0 times a specific gravity of the molding sand.
    Type: Application
    Filed: September 27, 2011
    Publication date: July 25, 2013
    Applicants: NIKKO CASTING CO., LTD., THE JAPAN STEEL WORKS, LTD.
    Inventors: Daisuke Tomigashi, Yoshikazu Itabashi, Seiji Kubo
  • Patent number: 8490677
    Abstract: The present inventions provide a method for forming molds and a core which generates no gases with bad effects on the human bodies while the binders are heated. In particular, the present inventions provide a method for forming molds and a core comprising an aggregate material mixture consisting of granular aggregate materials, wherein the aqueous binders and water are foamed with stirring, filled into a space for forming molds, and caked with an evaporating water component. In an embodiment, molds can be further cured by adding cross linking agents before and after they are taken out from the space for forming. Further, an aggregate material mixture for forming molds used for the method for forming molds of the present inventions is provided.
    Type: Grant
    Filed: August 31, 2004
    Date of Patent: July 23, 2013
    Assignee: Sintokogio, Ltd.
    Inventors: Toshihiko Zenpo, Yusuke Kato, Norihiro Asano, Masahiko Nagasaka, Kazuyuki Nishikawa
  • Publication number: 20130105103
    Abstract: The present invention provides a structure for casting containing an organic fiber, an inorganic fiber, inorganic particles (A) having an average particle diameter of 50 to 150 ?m, and a binder (a), having a surface layer containing refractory inorganic particles (B) having an average particle diameter of 1 to 100 ?m selected from metal oxides and metal silicates, a clay mineral, and a binder (b), on the surface of the structure.
    Type: Application
    Filed: June 24, 2011
    Publication date: May 2, 2013
    Applicant: KAO CORPORATION
    Inventor: Haruki Ikenaga
  • Publication number: 20130098574
    Abstract: Heat flow and mechanical strength of an engine component are improved by an organic-like casting core. Hardened granules are formed of a core material having a three-dimensional solid shape. A secondary binder is applied to the hardened granules. A multiplicity of the granules are agglomerated in a master mold in a shape of a water jacket of the engine component, and the secondary binder is hardened to form an organic-like core having a continuous web structure. A plurality of other cores are formed in respective master molds to define respective surfaces of the engine component. The organic-like core is assembled with the other cores to form a casting mold. The engine component is cast by flowing molten metal into the casting mold, thereby forming a continuous parent metal bridging the water jacket having a predetermined porosity. The core material is removed from the engine component after casting.
    Type: Application
    Filed: October 25, 2011
    Publication date: April 25, 2013
    Applicant: FORD MOTOR COMPANY
    Inventor: Charles Fabros
  • Patent number: 8387683
    Abstract: The present invention provides a structure for producing cast articles containing one or more inorganic particles selected from amorphous and artificial graphites, an inorganic fiber and a thermosetting resin and having a gas permeability of 1 to 500.
    Type: Grant
    Filed: January 15, 2009
    Date of Patent: March 5, 2013
    Assignee: Kao Corporation
    Inventors: Akira Yoshida, Masayuki Osaki, Toshiki Matsuo, Tomofumi Kanzawa
  • Publication number: 20120132391
    Abstract: The object of the present invention is to provide a method for green sand molding that prevents a bad casting by producing a mold that does not have a brittle surface. The method comprises the steps of filling the green sand into a flask while fluidizing the green sand by aeration at a pressure between 0.05 and 0.18 MPa, and squeezing the green sand that has been filled in the flask, wherein a mold is produced so that the friability of the mold is 10 or less. The friability is a value that is calculated by the following steps: putting the mold in a rotating cylindrical sieve that has a diameter of 177.8 mm and USA sieve size No. 8, rotating the cylindrical sieve at 57 rpm for 60 seconds, dividing the weight of the sand that has passed through the sieve by the weight of the sand that has been put into the sieve, and multiplying the quotient by 100.
    Type: Application
    Filed: July 25, 2011
    Publication date: May 31, 2012
    Applicants: Western Michigan University, SINTOKOGIO, LTD.
    Inventors: Hiroyasu MAKINO, Sam Ramrattan
  • Patent number: 8151860
    Abstract: A metal article containing at least 10% interconnected porosity is produced by using a preform. To make the preform, an organic binder, a wetting agent and a granular material are mixed to obtain a mouldable paste that combines 10 vol. pct. or more of the granular material, this material dissolving easily in a liquid solvent. The paste is shaped into an aerated preform, thus creating an open pore space to be infiltrated by the metal or alloy. The wetting agent is evaporated and the preform is baked to a temperature sufficient to degrade the binder and create a network of interconnected open porosity in the preform. Then, the open pore space is filled with the liquid metal or alloy. All or part of the baked preform can be easily leached by a liquid solvent through the network of fine pores.
    Type: Grant
    Filed: February 15, 2008
    Date of Patent: April 10, 2012
    Assignee: Ecole Polytechnique Federale de Lausanne (EPFL)
    Inventors: Andreas Mortensen, Russell Goodall
  • Publication number: 20120048502
    Abstract: In a method for producing a salt core for casting formed by a molten salt made of a salt mixture containing sodium salt, first, a melt is formed by heating a salt mixture. Next, a mold for core molding is heated to a temperature higher than about 0.52×Tm and lower than about 0.7×Tm. Note that Tm represents the liquidus temperature of the salt mixture as an absolute temperature (K). Then, the melt is poured under pressure into the mold heated as described above. A salt core for casting is molded by solidifying the melt inside the mold.
    Type: Application
    Filed: April 30, 2010
    Publication date: March 1, 2012
    Applicants: YAMAHA HATSUDOKI KABUSHIKI KAISHA, NATIONAL UNIVERSITY CORPORATION TOHOKU UNIVERSITY
    Inventors: Koichi Anzai, Katsunari Oikawa, Youji Yamada
  • Publication number: 20110293434
    Abstract: A method of casting a component (42) having convoluted interior passageways (44). A desired three dimensional structure corresponding to a later-formed metal alloy component is formed by stacking a plurality of sheets (18, 20) of a fugitive material. The sheets contain void areas (22) corresponding to a desired interior passageway in the metal alloy component. A ceramic slurry material is cast into the three dimensional structure to form either a ceramic core (34) or a complete ceramic casting vessel (38). If just a ceramic core is formed, a wax pattern is formed around the ceramic core and an exterior ceramic shell (38) is formed around the wax pattern by a dipping process prior to the removal of the fugitive material and wax. An alloy component having the desired interior passageway is cast into the casting vessel after the fugitive material is removed.
    Type: Application
    Filed: April 15, 2011
    Publication date: December 1, 2011
    Inventors: Ching-Pang Lee, Gary B. Merrill, Andrew J. Burns
  • Publication number: 20110275758
    Abstract: The present invention relates to modified phenolic resins which contain silicic acid ester units. The modified phenolic resins may, for example, be used as components of a foundry binder system. The invention also relates to a method for producing such modified phenolic resins and to two-component binder systems which contain these modified phenolic resins. The invention furthermore relates to methods for producing foundry molds and foundry cores which contain the modified phenolic resins, and to the foundry molds and foundry cores themselves.
    Type: Application
    Filed: June 21, 2011
    Publication date: November 10, 2011
    Applicant: Huttenes-Albertus Chemische Werke GmbH
    Inventors: David Strunk, Gerard Ladegourdie, Frank Lenzen
  • Patent number: 8011419
    Abstract: Thermal expansion defects, i.e. veining, are reduced in iron, steel, and nonferrous castings by adding a lithia-containing material in a sufficient amount to the silica sand mold. Adjusting current formulations to maximize the use of lesser expensive raw materials and minimize the use of more expensive raw materials to lower the overall percentages of lithia/metallic oxide containing additives while still reducing or eliminating thermal expansion related defects in the metal casting process reduces the overall cost to manufacture the product.
    Type: Grant
    Filed: October 1, 2008
    Date of Patent: September 6, 2011
    Assignee: IGC Technologies, LLC
    Inventors: Jeffrey Jon Cieplewski, Andrew Callan, Rebecca Roti
  • Publication number: 20110174460
    Abstract: Provided is a method of manufacturing a casting for a mold for molding a tire, wherein twist and warp deformation of each block of the casting is less likely to occur when the casting shrinks, the difference between the degrees of shrinkage of cope and drag is small, the casting, even if large-sized, can be produced in a relatively short molten metal solidifying time, and healthy castings can be easily obtained. A method of manufacturing a casting for a mold for molding a tire of a sectional mold type in which the mold is opened and closed by dividing the mold into a plurality of pieces in the circumferential direction comprises a process of manufacturing each of divided block castings (1) by casting them individually.
    Type: Application
    Filed: June 15, 2009
    Publication date: July 21, 2011
    Applicant: BRIDGESTONE CORPORATION
    Inventor: Yasuyuki Ishihara
  • Patent number: 7938169
    Abstract: Additives to foundry sand cores are provided for reducing or eliminating surface defects called veins in metal castings, by reducing the propensity of sand mold and core aggregates to crack during metal casting. The additives generally include an iron oxide component such as magnetite and hematite and a glass component which is preferably free of lithium oxide. The additive may also optionally include an amount of carbon effective to reduce adhesion of sand particles to the casting.
    Type: Grant
    Filed: June 20, 2008
    Date of Patent: May 10, 2011
    Assignee: Prince Minerals, Inc.
    Inventors: Jon H. Attridge, Joshua M. Werling
  • Publication number: 20110100578
    Abstract: In production of a mold with the reclaimed spherical molding sand having a sphericity of 0.95 or more and mainly composed of Al2O3 together with the binder containing the acid-hardening resin and the hardening agent (I), at least one of the hardening agents (I) and (II) that is used in production of a mold from which the reclaimed molding sand is obtained contains the organic sulfonic acid, and in the hardening agent, a content of sulfuric acid is not more than 5% by weight and a content of phosphoric acid is not more than 5% by weight.
    Type: Application
    Filed: April 27, 2009
    Publication date: May 5, 2011
    Applicant: KAO CORPORATION
    Inventors: Yoshimitsu Ina, Shigeo Nakai, Toshiki Matsuo
  • Publication number: 20110025009
    Abstract: The invention relates to a chassis component for an automobile and a method for producing such chassis component. A mineral core body made of silicate is cast inside a light metal casting, and the blank produced in this manner is processed by forging, forming they chassis component 1. The density and strength of the base body of the light metal casting forming the chassis component as well as of the core body can be adjusted during the forging process.
    Type: Application
    Filed: July 29, 2010
    Publication date: February 3, 2011
    Applicant: Benteler Automobiltechnik GmbH
    Inventors: HANS-JÜRGEN NEUMANN, HERMANN LAUKÖTTER, WOLFRAM LINNIG
  • Patent number: 7832456
    Abstract: Three dimensional printing equipment and techniques may be used in combination with three dimensional design data associated with well drilling equipment and well completion equipment to form molds associated with manufacture of such equipment. For example, such molds may be used to form a bit body or other components associated with a rotary drill bit. For some applications composite or matrix materials may be placed in the mold to form a matrix bit body. Heat transfer characteristics of the mold may be optimized for heating and/or cooling of the matrix materials to provide optimum fracture resistant (toughness) and optimum erosion, abrasion and/or wear resistance for portions of the bit body. Such molds may also be used to form steel bit bodies associated with fixed cutter rotary drill bits and other components associated with a wide variety of well drilling equipment and well completion equipment.
    Type: Grant
    Filed: April 27, 2007
    Date of Patent: November 16, 2010
    Assignee: Halliburton Energy Services, Inc.
    Inventors: Barry D. Calnan, Valerie R. C. M. J. Sillen
  • Patent number: 7832457
    Abstract: Three dimensional printing equipment and techniques may be used in combination with three dimensional design data associated with well drilling equipment and well completion equipment to form molds associated with manufacture of such equipment. For example, such molds may be used to form a bit body or other components associated with a rotary drill bit. For some applications composite or matrix materials may be placed in the mold to form a matrix bit body. Heat transfer characteristics of the mold may be optimized for heating and/or cooling of the matrix materials to provide optimum fracture resistant (toughness) and optimum erosion, abrasion and/or wear resistance for portions of the bit body. Such molds may also be used to form steel bit bodies associated with fixed cutter rotary drill bits and other components associated with a wide variety of well drilling equipment and well completion equipment.
    Type: Grant
    Filed: October 19, 2007
    Date of Patent: November 16, 2010
    Assignee: Halliburton Energy Services, Inc.
    Inventors: Barry D. Calnan, Valerie R. C. M. J. Sillen
  • Publication number: 20100243197
    Abstract: A rotor for an induction motor and a method of preparing same. The method includes making a squirrel-cage rotor made up of a cage and a laminate stack by forming a mold around the stack, heating the stack and introducing a molten metal into the mold such that the molten metal substantially fills a space defined in the stack that corresponds to the cage. In one form, the space includes slots or related channels formed in the stack that upon filling with the molten metal become longitudinal bars that form electric current loops with end rings of the cage. By heating the stack and maintaining it at a temperature high enough to keep the molten metal in a substantially molten state at least long enough for it to flow through the slots of the stack, premature freezing of the molten metal is avoided. In addition, by providing low pressure to the molten metal in conjunction with the elevated temperature in the stack, flow is promoted to ensure a substantially porosity-free, fully dense squirrel-cage for the rotor.
    Type: Application
    Filed: March 24, 2009
    Publication date: September 30, 2010
    Applicant: GM GLOBAL TECHNOLOGY OPERATIONS, INC.
    Inventors: Mark A. Osborne, Barry L. Priem, Dale A. Gerard
  • Patent number: 7770629
    Abstract: The invention relates to a moulding mixture for producing casting moulds for metalworking, a process for producing casting moulds, casting moulds obtained by the process and also their use. To produce the casting moulds, a refractory mould raw material and a binder based on water glass are used. A proportion of a particulate metal oxide selected from the group consisting of silicon dioxide, aluminium oxide, titanium oxide and zinc oxide is added to the binder. Particular preference is given to using synthetic amorphous silicon dioxide as metal oxide.
    Type: Grant
    Filed: September 2, 2005
    Date of Patent: August 10, 2010
    Assignee: AS Lungen GmbH
    Inventors: Günter Weicker, Diether Koch, Jens Müller, Udo Skerdi, Henning Rehse, Anton Gienic, Reinhard Stötzel, Thomas Dünnwald
  • Publication number: 20100147485
    Abstract: The object of the present invention is to provide a mold which has low reactivity with molten alloys and which is inexpensive, a method for manufacturing the same and a molded article using the mold. A mold 40 in accordance with the present invention serves for manufacturing a molded article 60 of a titanium-aluminum alloy or a titanium alloy. At least an initial layer 44a of a cavity surface 43 of a mold body 41 constituting the mold 40 is formed of a calcined product of a slurry comprising a filler having cerium oxide as a main component and a binder having silica sol as a main component.
    Type: Application
    Filed: February 23, 2010
    Publication date: June 17, 2010
    Applicants: IHI CORPORATION, IHI Castings Co., Ltd.
    Inventors: Kazuyoshi Chikugo, Shigeyuki Sato
  • Patent number: 7712516
    Abstract: The molding material or molding part for foundry purposes, comprising 1-10% of binding agent based on alkali silicate, an aggregate containing 1-10 percent by weight of amorphous silicon dioxide, remainder quartz sand with a grain size range of 0.01 to 5 mm, and to a process of producing a molding material and molding parts. The abstract of the disclosure is submitted herewith as required by 37 C.F.R. §1.72(b). As stated in 37 C.F.R. §1.72(b): A brief abstract of the technical disclosure in the specification must commence on a separate sheet, preferably following the claims, under the heading “Abstract of the Disclosure.” The purpose of the abstract is to enable the Patent and Trademark Office and the public generally to determine quickly from a cursory inspection the nature and gist of the technical disclosure. The abstract shall not be used for interpreting the scope of the claims.
    Type: Grant
    Filed: August 1, 2007
    Date of Patent: May 11, 2010
    Assignee: Minelco GmbH
    Inventor: Ralf-Joachim Gerlach
  • Patent number: 7677297
    Abstract: Residual stress is reduced in light metal alloy articles, e.g. aluminum alloy articles, formed as castings against a sand casting mold body by incorporating a wax composition of suitable softening or melting temperature with the sand particles of the mold or core body. The hot cast metal heats adjoining surfaces of the mold body. As the cooling metal forms a solid shell, the surrounding sand particle and wax mixture are heated sufficiently to melt or soften the wax incorporated on or between sand particles. This softens portions of the rigid mold body that could otherwise restrain shrinking surfaces of the casting and produce unwanted stressed regions that are retained in the casting and must be removed by subsequent processing.
    Type: Grant
    Filed: June 29, 2007
    Date of Patent: March 16, 2010
    Assignee: GM Global Technology Operations, Inc.
    Inventors: Suresh Sundarraj, Parag Agarwal, Anil K. Sachdev
  • Publication number: 20100021758
    Abstract: A process for producing a metal article containing at least 10% interconnected porosity, using a preform (11), comprising: mixing an organic binder, a wetting agent and a granular material, to obtain a mouldable paste that combines 10 vol. pct. or more of said granular material, said material dissolving easily in a liquid solvent; shaping the paste into an aerated preform and providing an open pore space to be infiltrated by the metal or alloy; evaporating said wetting agent and baking said preform to a temperature sufficient to degrade the binder and create a network of interconnected open porosity in the preform; filling said open pore space with the liquid metal or alloy. All or part of the baked preform can be easily leached by a liquid solvent through the network of fine pores.
    Type: Application
    Filed: February 15, 2008
    Publication date: January 28, 2010
    Applicant: ECOLE POLYTECHNIQUE FEDERALE DE LAUSANNE (EPFL)
    Inventors: Andreas Mortensen, Russell Goodall
  • Publication number: 20090314461
    Abstract: Additives to foundry sand cores are provided for reducing or eliminating surface defects in metal castings. The additives generally comprise an iron oxide component and a glass component which is preferably free of lithium oxide.
    Type: Application
    Filed: June 20, 2008
    Publication date: December 24, 2009
    Applicant: Prince Minerals, Inc.
    Inventors: Jon H. Attridge, Joshua M. Werling
  • Publication number: 20090242160
    Abstract: Methods of forming modulated capacity scroll compressors are provided, where at least two distinct mold shapes are formed of foam material and then joined together to form a mold assembly. The mold assembly defines one or more substantially horizontal features, such as a horizontally oriented fluid passage or a weight-reduction recess in a solid wall. In certain aspects, the mold assembly defines a junction between a portion of a horizontal fluid passage and a portion of a vertical fluid passage. A molten metal displaces the foam material of the mold assembly to solidify and form the scroll component.
    Type: Application
    Filed: March 27, 2009
    Publication date: October 1, 2009
    Inventors: Richard A. Obara, Pride R. Bruner
  • Publication number: 20090095439
    Abstract: The invention relates to a molding composition for producing casting molds for the foundry industry, comprising at least: a refractory mold material; a binder for curing the molding composition; a proportion of a borosilicate glass. The invention further relates to a process for producing a molding from the molding composition of the invention, the corresponding casting mold or the corresponding molding and also their use in metal casting.
    Type: Application
    Filed: September 1, 2006
    Publication date: April 16, 2009
    Applicant: ASHLAND-SUDCHEMIE-KERNFEST GMBH
    Inventors: Reinhard Stotzel, Diether Koch, Antoni Gieniec, Jens Muller, Gunter Weicker, Hans-Jurgen Werner
  • Publication number: 20090050286
    Abstract: A rare earth-based core for use in the casting of a reactive metal is described. The core contains a ceramic composition which includes at least about 10% by weight of monoclinic rare earth aluminate (RE4Al2O9), wherein RE represents at least one rare earth element; and at least about 10% by weight of at least one free rare earth oxide. The ceramic phase of the composition may include a microstructure which comprises a multitude of substantially spherical pores which are formed as a result of the removal of aluminum metal from the core composition during a heat treatment step. Additional embodiments relate to a method for the fabrication of a ceramic core, employing a rare earth oxide, aluminum metal, and a binder. Methods for removing cores from a cast part are also described.
    Type: Application
    Filed: August 24, 2007
    Publication date: February 26, 2009
    Applicant: GENERAL ELECTRIC COMPANY
    Inventors: Bernard Patrick Bewlay, Stephen Francis Bancheri, Frederic Joseph Klug
  • Publication number: 20080190583
    Abstract: A chill mould for the casting of light metal casting materials is provided. The chill mould is manufactured from an Ni-alloyed and/or Mn-alloyed cast iron material, of which the Ni and/or Mn content is dimensioned in such a way that the thermal coefficient of expansion of the chill mould is adjusted to the thermal coefficient of expansion of the light metal casting material, which is to be cast in each case. A chill mould is provided which can be manufactured in an economical manner which possesses optimized properties of use and at the same time allows for optimized casting results. Such a chill mould can be a constituent part of a sand casting mould for the casting of a cylinder block from a light metal casting material.
    Type: Application
    Filed: January 27, 2006
    Publication date: August 14, 2008
    Applicant: Hydro Aluminium Deutschland GmbH
    Inventors: Jurgen Trumper, Herbert Smetan
  • Publication number: 20080169083
    Abstract: A sand-introducing device that uses air for introducing molding sand in a molding space or spaces is provided. The device is provided with air-permeable partitioning plates that define a double-walled structure together with the wall of the body of the device. The air-permeable partitioning plates are easily produced, they can easily inject pressurized air of a desired pressure, and they will not need regular maintenance. The body of the device, which acts as a pressure tank, defines a double-walled structure together with the air-permeable partitioning plates (10, 11), thereby defining chambers (12, 13). In the sand-introducing device that uses air, while molding sand is fluidized by pressurized air injected from the air-permeable partitioning plates, it is introduced in a molding space. Each air-permeable partitioning plate is made of a porous resin or metal.
    Type: Application
    Filed: July 30, 2007
    Publication date: July 17, 2008
    Inventors: Hisashi Harada, Takuya Nitta, Takashi Hanai, Minoru Hirata, Kozo Sugita, Toshihiko Oya
  • Publication number: 20080121365
    Abstract: Techniques for forming cast parts for medical devices suitable for contact with internal regions of patients are described herein. Such parts can be small in scale (e.g., having a major axis less than 0.3 inches, and/or a minor axis less than about 0.08 inches), and can be formed from metals that have a high melting point and high reactivity with environmental components or mold surfaces, such as stainless steel and titanium alloys. Such techniques can include injecting molten metal into the sprue of a mold tree such that the side runners are backfilled after the molten metal impacts a closed end of the sprue. Side runners can be oriented in particular directions and positions to promote backfilling. As well, flask temperatures and the use of surfactants can also promote cast part formation, hindering the formation of surface defects.
    Type: Application
    Filed: December 3, 2007
    Publication date: May 29, 2008
    Applicant: ETHICON ENDO-SURGERY, INC.
    Inventors: William A. Crawford, Tracy J. Potter, Donald F. Heaney, Brian S. DeForce, Samardh Onukuri