Abstract: The invention provides a neck-down feeder of unitary construction for use in metal casting. The feeder comprises a body portion integrally formed at a first end thereof with a tapered base portion for mounting on a mould pattern. The body portion and the base portion are defined by a continuous sidewall having one or more regions of weakness arranged such that the feeder is breakable in use whereby at least a part of the base portion detaches from the body portion and is received therein.

Abstract: A mold for creating metal ingots, a hottop sideboard and a system and method of manufacturing metal ingots utilizing the same. A hottop sideboard utilizes a layer of a rigid refractory material integrally connected to a layer a flexible refractory material that is compressed between the rigid layer and the sidewalls of the mold during use. The mold for creating metal ingots comprises: a main body having a floor and sidewalls that form a cavity for receiving a molten metal; a plurality of sideboards connected to the sidewalls and forming a perimeter about the cavity in a spaced relation from the floor, the sideboards comprising a first layer of a rigid refractory material and a second layer of a flexible refractory material, the first layer and the second layer being connected to one another; and the sideboards are secured to the sidewalls so that the second layer is compressed between the first layer and the sidewall.

Abstract: An exothermal weld mold includes a mold section with an integral cover portion, made as part of a single piece of material with the rest of the mold section. The mold section may be a mold half of a vertically split mold, or may constitute most of a half of the mold. The cover portion may be part of an integral cover that covers substantially all of a reaction chamber or crucible of the mold. The cover may have one or more vent holes, in the top and/or side of the mold. The cover may have a baffled passage for expansion of gases produced by reaction of the weld material, before the gases are expelled from the mold at an opening in the top or side of the mold. The passage may be a serpentine passage. A filter may be placed in the passage.

Abstract: This invention relates to an improved process for casting a metal by pouring molten metal into and around a casting assembly, where a riser containing a sleeve is a component of the casting assembly. The process comprises (a) inserting a riser insert into the cavity of the riser containing the sleeve, and (b) then allowing molten metal to flow into the cavity of the riser containing the riser insert. The density of the riser insert is such that the riser insert floats on the surface of the molten metal when the molten metal enters the cavity of the riser and provides a thermal barrier to reduce heat loss from the riser. The sleeve is shaped such that the riser insert will not be forced out or float off of the riser cavity when the metal is poured.

Abstract: A mold for hot-top vertical continuous casting of metals includes a feed head (8) made of a thermally insulating refractory material which surmounts a cooled copper crystallizer (9) and is internally aligned with a cooled copper element (14) of the cooled copper crystallizer (9) in order to define a calibrating passage for the cast metal. The copper element (14) is formed by an assembly of plates, some of which, termed “large walls”, are each held against a reinforcing backplate (16) to which it is rigidly fastened by a clamp (22), the shape of which is elongate in the width direction of the large wall and which goes over the top of the large wall and its associated backplate.

Abstract: A riser sleeve with a breaker core comprises a sectionally V-shaped riser sleeve having a bottom opening and a breaker core having a central opening and attached to the bottom of the riser sleeve. The inner diameter D.sub.3 of the central opening of the neck-down core is substantially the same as the inner diameter D.sub.2 of the bottom opening of the riser sleeve, and the outer diameter D.sub.5 of breaker core is substantially the same as or larger than the outer diameter D.sub.4 of the bottom of the riser sleeve. The riser sleeve with breaker core greatly reduces the amount of finishing that the cast product requires after casting.

Abstract: A hot top lining assembly for an ingot mould or for an ingot mould head box is made up of four boards of refractory material and fixed together by means of a guide bar incorporated in a wedge-shaped portion in the lateral edge of one of the boards mating with a slot in a lateral edge of an adjacent board.

Abstract: The hot top utilizes an integral angle iron structure connected to the hot top for avoiding seal leaks of molten metal through the space between the bottom portion of the hot top and the top of the mold wall. By providing the angle iron structure with a plurality of holes which allow the cooling ingot metal to tear out portions of the structure as the ingot contracts, such structure also allows the cooling ingot to move downwardly in the mold and to separate from the structure, thereby preventing hanger cracks from occurring.

Abstract: A feeder sleeve (1') for use in the casting of molten metal has a cavity (8) whose cross-sectional area at the bottom of the cavity (8) is greater than the cross-sectional area at the top of the cavity (8) such that a line joining a point (11.1) on the inner surface (11) of the sleeve at the bottom of the cavity (8) and the nearest point (11.2) on the inner surface (11) of the sleeve at the top of the cavity (8) is less than 80.degree. to the horizontal. The inner surface of the sleeve may taper from the bottom of the cavity to the top of the cavity uniformly or in at least one step (12).

Abstract: A reusable hot top includes a shell having an aperture therethrough providing an inner wall. The shell has an upper end portion and a lower end portion which seats on a mold. A liner comprised of an insulating material is positioned in the aperture and is movable relative to the upper and lower end portions. Insulation is sandwiched between the liner and the inner wall and prevents heat conductance between the liner and the shell. Pins extend from the inner wall and are engaged with and support lugs extending from the liner and thereby maintain the liner in the aperture when the shell is lifted from the mold and the pins are disengaged from the lugs when the shell is seated on the mold. A thermal seal is disposed around the bottom of the liner and contacts the mold. The seal prevents the liner from contacting the mold and thereby prevents heat conductance between the liner and the mold.

Abstract: Molten metal is cast in a mould having a feeder cavity, which may be defined by a feeder sleeve, whose surface has a plurality of elongate projections or ribs spaced apart around its perimeter, the number and dimensions of the ribs being such that the volume of the feeder cavity is reduced by at least 20% compared to a feeder cavity of generally the same size and shape but without the ribs. Preferably the ribs extend substantially the full length of the inner surface of the feeder sleeve. The sleeve may have for example four ribs whose shape and size is such that the horizontal cross-section of the feeder cavity defined by the sleeve is cruciform. The ribs may be formed of material having an exothermic, an exothermic and heat-insulating, or a heat-insulating composition. The ribs enable a given casting to be fed from a smaller quantity of feeder metal than is usual.

Abstract: A formwork system (10) comprising frame elements (11), posts (12) for arrangement between the frame elements if necessary locking means (21), together with formwork sides (13). The frame elements are designed with longitudinal grooves (15) and/or keys at least in the sides which face towards the posts (12) for engagement with corresponding keys or slots in the post. The front side of the formwork side (13) after arrangement in the frame element is flush with the front side of the post, either in that the corners on the front side of the post, parallel to the key (18) or the groove, are designed with a longitudinal notch having a depth which is equal to the thickness of the formwork side or in that there is arranged on the inside of the frame element a longitudinal flange (16) at a distance from the front edge of the element equal to the thickness of the formwork side (13). On formworking of a pavement the key (18) and the groove (15) respectively have an angled cross-sectional form.

Abstract: In the ingot casting of killed-steel steels, insulative walled reservoirs known as hot-tops are employed at the top of the mold to maintain a source of molten steel which can feed the shrinkage cavity that forms during solidification of the ingot. Presently, these hot-tops are set to a predetermined height prior to the filling of the mold cavity. As a result of such controlled height pourings, variations in the volume of the mold cavity lead to significant losses in the ingot-to-product yield. To overcome such losses, the invention employs a floating hot-top. Rather than teeming to a prescribed height, the ingot is teemed to a prescribed weight and the floating hot-top is placed on the surface of the steel so teemed. Further pouring is delayed, at least until the hot top is welded to the surface by the freezing of the molten steel in contact therewith. Thereafter, the hollow center of hot-top is filled to provide a sufficient reservoir of molten metal for the resultant shrinkage cavity.

Abstract: A disposable hot top board includes a compressible seal positioned along the outer surface of the board to form a seal between the bottom of the board and the mold wall. In a preferred form, the disposable hot top board comprises an insulating or exothermic material having a reticulated metal mesh embedded therein. A metal plate extends along at least a portion of the outer surface and a ceramic fiber strip extends along a bottom portion of the board. A perforated metal retention strip with a first end interwoven with the mesh and a second end extending outward from the board, is used with a big end up mold having a pair of slots. In addition to the standard internal wedge system, the board is forcibly retained against the ingot mold to compress the fiber strip into a seal by a rod which engages the metal retention strip in a wedging type relationship with the mold exterior.

Abstract: A casting riser including a top support member and an internal support member to receive the high pressure molding forces to enable the casting riser to withstand the high pressure molding forces.

Abstract: The ingot mould comprises a hot-top positioned inside the upper part of the mould and comprising an inner wall formed by at least one plate of a material capable of withstanding contact with a molten metal poured into the ingot mould, without being melted or fused. The thickness of the inner wall is less than that of the wall of the mould, at least one recess is provided inside the upper part of the mould wall and the inner wall of the hot-top is placed in the recess, with its surface essentially flush and aligned with the inner surface of the mould, so as to form a closure wall separating the interior of the recess from the interior of the mould.

Abstract: The exposed surface of a molten metal, ferrous or non-ferrous in a ladle is covered by an expanding insulating ladle covering compound that is capable of absorbing and removing non-metallic inclusions in a predictable volume. The compound includes burnt lime in amounts between 56% and 60% by weight, aluminum dross, including Al.sub.2 O.sub.3 in amounts between 22% and 30% by weight, fluorspar in amounts between 7% and 9% by weight, and acid treated graphite in amounts between 1% and 4% by weight.

Abstract: A hot top casing for cooperation with an ingot mold body is provided having a depending portion from which a pair of trunnions extend away from the casing and a second pair of trunnions extend toward said casing whereby each of said pairs are displaced vertically with respect to the center of gravity with one pair above and one pair below said center.

Abstract: A hot top consists of a number of sheets of insulating fibrous material. The principally vertical walls of the hot top consist of a number of sheets located close to and joined to one another. When the hot top is placed in an ingot mould, these sheets cover the upper part of the ingot mould walls. The hot top has an upper confinement consisting of one or more sheets of insulating fibrous material which cover the opening formed by the vertical sheets. One or more containers holding additives used in casting are arranged in the space under the confinement. In one preferred embodiment, the walls of the hot top, the upper confinement of the hot top and the hot top containers holding additives form a single unit matched to the dimensions of the ingot mould, so that in a preferred embodiment, the unit is assembled before the hot top is inserted into the ingot mould.

Abstract: A hot top lining for use in casting metal ingots is positioned in the mouth of the mould or in a head box at the top of the mould and comprises a plurality of refractory, heat-insulating lining slabs at least one of which has, at its outward-facing surface and adjacent to its lower edge, at least two ribs extending horizontally across the slab to inhibit upward flow of molten metal behind the slab. The ribbed slabs themselves form a part of the invention.

Abstract: A novel hot top mounting method is disclosed for use in attaching insulation to the upper interior portion of an ingot mold. The mounting method comprises (1) applying a plurality of thin steel mounting straps to the insulation and suspending the insulation in position adjacent to the upper interior surfaces of the mold, and (2) driving fasteners through the mounting straps and into the mold in order to securely fasten the insulation to the mold.

Abstract: A hot top for an ingot mold has a plurality of sections mateable along adjoining edges. The sections include two diametrically opposed lift sections engageable by a crane for transporting the hot top and an intermediate section fitting between corresponding ends of the lift sections. A tongue and groove joint is provided along the adjoining edges of the sections to make them readily detachable and facilitate interchange of sections of different lengths. The joint is tapered in the longitudinal direction from top to bottom of the edges so as to transmit an upward force to the intermediate sections when the lift sections are raised thus preventing separation of the sections when the hot top is transported.

Abstract: An exothermic anti-piping composition of the type which is formed of a refractory heat-insulating material, an exothermic compound, and an expanding media, and wherein the expanding media is predominantly either vermiculite ore or perlite ore along with less than 1% by weight of acid-treated graphite flakes.

Abstract: A corner wedging consumable hot top for ingot molds is formed of four side board sections and four corner wedges made of a combustible consumable material capable of being wedged in opposed relation within an ingot mold so that the hot top formed thereby conforms with the cavity shape in the ingot mold and when ignited by the molten metal poured therein supplies heat to maintain a pool of molten metal as necessary for filling cracks and pipes in the cooling ingot.

Abstract: The invention provides shaped, refractory, heat-insulating articles, for use in a metallurgical vessel, comprising particulate refractory material, binder and particulate de-fibred bagasse or the like. The articles may be made by mixing the ingredients, pressing them in a former and causing or allowing the binder to set. The articles may be slabs for lining the head of a mould for steel ingots.

Abstract: An improved casting riser is provided of two different materials, an upper portion having a low thermal conductivity for retaining the heat of the metal in the riser liner and a lower portion having a high thermal conductivity to allow transfer of heat between the molten metal in the riser liner and the molten metal in the mold.

Abstract: An expandable hot top for use in ingot moulds has six panels hinged to one another, two pairs of which are arranged to be folded inward with accordion-like folds for simplified placement and registry within the ingot mould and to form a compact flat form for shipping.

Abstract: A breaker core for use in metal casting is described. The core is located in a casting mould between a riser and the cavity corresponding to the casting. The core consists of a base having an aperture (which defines a neck between the casting and the solidified metal in the riser) and means for frictional engagement with a casting riser lining sleeve or with a casting riser cavity. The base may have a recess which receives a projection extending from the sleeve or an upstanding lip at or somewhat spaced from the edge of the base for engagement with an inner or an outer wall of the riser sleeve.

Abstract: A feeding unit comprising a breaker core and a riser sleeve. In a first embodiment the breaker core has a thickness of 10% of the diameter of the riser sleeve and the opening in the breaker core is from 20% to 35% of the riser sleeve diameter.In another embodiment of the invention the breaker core opening is tapered inwardly and downwardly in a generally v-cross sectional shape and one embodiment of the invention will have a symmetrical v-cross sectional area.

Abstract: A self adjusting consumable hot top is formed of a pair of bendable shape adjusting sections of a combustible consumable material capable of being wedged into opposed relation in an ingot mold so that the hot top conforms with the shape of the cavity in the ingot mold and when ignited by molten metal poured therein adds heat to the molten metal to maintain a pool of molten metal for filling pipes and cracks in the cooling ingot.

Abstract: Preparation of particulate metallurgical hot topping compositions that react in situ to form a protective cover over the exposed surface of as-cast ingots. The compositions consist essentially of 9 to 33 percent by weight of oxidizing constituents, 40 to 65 percent by weight refractory constituents and 15 to 45 percent by weight of fuel constituent. Careful control of the quality and size of the major fuel constituent minimizes smoke evolution during reaction of the composition and subsequently if the covering is disturbed. By varying the ingredients in the hot topping composition, there can optionally be produced (1) a hard crust so that the as-cast ingots can be moved before a major portion of the ingot has solidified (2) a medium density crust for delayed addition of a highly exothermic hot topping composition, or (3) a low strength crust for "back-pouring" practice.

Abstract: Flexible hot topping liners having improved properties comprise refractory, deformable, self-supporting, fibrous liners which have, in their dry condition, flexibility, restitution and droop characteristics within certain defined ranges. In the preferred embodiment, the extensibility and compressibility properties are also maintained within defined ranges. Flexible sealing rings for sealing the joint between a headbox and an ingot mould are also disclosed.

Abstract: A mould assembly for casting molten metal which comprises a book mould, the upper parts of the walls of the upwardly open cavity of which are lined with hot top lining material and wherein extending across the width of the cavity there are one or more bridges of hot top lining material maintaining the hop top lining material along the longer walls of the cavity in contact with those longer walls.

Abstract: A process of manufacturing killed steel ingots of superior quality by forming the sound hot top portion and reducing the concentration of nonmetallic inclusion in the mushy zone of ingot bottom, characterized by arranging on the molten steel surface immediately after the pouring of the molten steel into a mold, a board-like molded heat-retaining material in which lining of a layer consisting of easily-flammable material is made to an exothermic, diabatic layer consisting of crushed flat charcoal, a refractory material expansible by heating and a binder.

Abstract: A heat-insulating and retaining molding for hot tops of a hollow monoblock type for placing on the upper end of a ingot mold at the time of making steel ingots, characterized by the construction of a hollow monoblock molding having homogeneous composition, comprising an organic fibrous material, an inorganic fibrous material, a refractory material and an organic binding material, said molding having in its longitudinal section, an inner structure laminated in the longitudinal direction extending along its inner and outer surface and constituting the thickness of the molding, or the inner side portion of said molding having an inner structure laminated in the longitudinal direction along the inner surface of the molding.

Abstract: A composition for use in the manufacture of thermally insulating, refractory articles, containing particulate refractory material and from 1 to 20 percent by weight of fibrous organic material, for example paper fibers and/or cardboard fibers, is made with a plastic consistency. For example, the composition is made with a consistency or apparent viscosity of at least 200,000 centipoises at 25.degree. C. Methods of making the composition and for making articles from the composition are also described.

Abstract: A moulding for the heat retention of feeder head top surface in casting molten metals is based on a mixture consisting of charcoal and a binder, and said charcoal is laminated with directional properties in the lateral direction. If circumstances require, the moulding may contain at least one component selected from the group consisting of thermo-expansible materials, organic binders and organic fibrous materials, and further when occasion demands it may be coated with a shell containing fibrous materials and a binder.

Abstract: Flexible hot topping liners having improved properties comprise refractory, deformable, self-supporting, fibrous liners which have, in their dry condition, flexibility, restitution and droop characteristics within certain defined ranges. In the preferred embodiment, the extensibility and compressibility properties are also maintained within defined ranges. Flexible sealing rings for sealing the joint between a headbox and an ingot mould are also disclosed.