Abstract: An ingot mold with mold wall and stool shields and the method of installing the mold wall and stool shields to the ingot mold and stoll. The mold wall shield comprises at least two portions connected by a bend. The mold wall shield and the stool shield can be multi-layered to provide a thin envelope or layer of air between the parallel layers. The shields are nailed to the mold or stool by an explosion actuated hammer. The mold wall shield is installed with the bend near the intersection between the mold and the stool. The shields are made of similar material to that being cast and melt due to the heat of the molten metal in the mold.

Abstract: A light weight ingot mold mat for receiving molten metal is formed from sheets of metal compatible with the molten metal. The sheets have closely spaced holes therein throughout most of their area so that they are very light and easily crumbled to form a honeycombed structure. The mat is placed on the mold stool and absorbs the force of the molten metal and chills it so that it freezes sufficiently to seal the joint between the stool and mold. The mat is melted and absorbed into the ingot.

Abstract: A laminated plate assembly (17) for protecting the mold stool (11) or bottom (125) of an ingot mold (10 or 100) during the pouring of molten metal therein, the assembly comprising spaced-apart plates (20, 21 and 22) secured together by embossments (24) or the like.

Abstract: A device for mitigating the splashing of droplets of molten metal during the pouring of same into a mould comprises a strip or strips of material which form a system of polygonal cells. The device is for vertical location with the strips edgewise in the base of a mould and fulfills the function of either a splash-guard when casting direct or a float when bottom-casting.

Abstract: In direct pouring of molten metal for an ingot-making process, hollow long bodies made from self-fluxing heat-resistant sheets are used as a splash-preventive pipe. The self-fluxing heat-resistant sheet is composed of one or more inorganic fibers having fixed softening and fusion temperatures, binders and silicate fillers. The fusion rate and temperature of the sheet are selected in accordance with the teeming rate and temperature to insure that the body end is fused and consumed while being submerged in a given depth below the molten metal surface in a mold.

Abstract: A device is provided for protecting the inner walls of casting molds, particularly molds of the permanent type which are filled by top pouring of the molten casting material thereinto, and for improving the surface quality of the castings formed in the mold. The device is formed from material which enables the device to be integrated into the casting formed in the mold and the protective device is configured with a bottom plate and a pair of laterally spaced upstanding side walls formed of sheet material. The protective device is placed in the bottom of the mold cavity and is located directly beneath the jet of molten casting material being poured into the mold. A wire lattice may be placed upon the protective device spaced above the bottom plate thereof or an upstanding tubular socket may be formed on the bottom plate.

Abstract: A shock absorber pad of molded fibers for the drop casting of ingots, comprising a plate of molded fibers having an assembly of truncated cups disposed in files and rows connected by thick webs along their upper edges. The webs are perforated between the cups and have concave cylindrical ribs for stiffening purposes. The cups and ribs in one file or row are so dimensioned as to nest into the cups and ribs of the opposite edge of an adjacent pad. The bottoms of the cups can be solid or perforate.

Abstract: A method of casting an ingot which comprises locating in an ingot mould a vertical tube of fibrous heat-insulating material of melting point less than the casting temperature of the metal of the ingot, and teeming molten metal into the mould.

Abstract: A splash can for placement in a mold before pouring molten metal into the mold, so as to eliminate scab producing splashes during pouring into the ingot mold. The top of the mold typically has a mouth of reduced diameter and the splash can of the present invention is of cylindrical form having a diameter greater than the mouth. The can is formed from material compatible with the molten material and deformable so that the can can be folded for introduction into the ingot mold through the mouth without exceeding the elastic limit of the material. The can is retained in the folded position by a tension member that is wrapped therearound; after the folded can is introduced into the mold, the tension member is severed whereupon the can springs into a generally cylindrical shape within the mold.

Abstract: Ingot casting splashcans are formed of a composition which melts during teeming of the ingot to form a molten casting flux.