GB2265099A - Consumable cluster of patterns at several layers; precision casting - Google Patents

Consumable cluster of patterns at several layers; precision casting Download PDF

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Publication number
GB2265099A
GB2265099A GB9305015A GB9305015A GB2265099A GB 2265099 A GB2265099 A GB 2265099A GB 9305015 A GB9305015 A GB 9305015A GB 9305015 A GB9305015 A GB 9305015A GB 2265099 A GB2265099 A GB 2265099A
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GB
United Kingdom
Prior art keywords
casting
metal
patterns
parts
consumable
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
GB9305015A
Other versions
GB2265099B (en
GB9305015D0 (en
Inventor
Pascal Sourlier
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Pont a Mousson SA
Original Assignee
Pont a Mousson SA
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Pont a Mousson SA filed Critical Pont a Mousson SA
Publication of GB9305015D0 publication Critical patent/GB9305015D0/en
Publication of GB2265099A publication Critical patent/GB2265099A/en
Application granted granted Critical
Publication of GB2265099B publication Critical patent/GB2265099B/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/08—Features with respect to supply of molten metal, e.g. ingates, circular gates, skim gates
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/02—Sand moulds or like moulds for shaped castings
    • B22C9/04—Use of lost patterns
    • B22C9/046—Use of patterns which are eliminated by the liquid metal in the mould

Abstract

A casting installation for use in precision casting of metal alloy parts comprises a mould (1) formed of a cluster of (10) of patterns (2) embedded in a granular material (3), the patterns (2) forming several levels (4, 5). The installation has application to massive parts and/or a large number of parts. Each level has an independent metal feed through downgates 6, 7 so that the flow to each level can be controlled by correct dimensioning of each of the downgates. The levels may be fed with metal from a single casting pouring basin. <IMAGE>

Description

METHOD AND INSTALLATION FOR CONSUMABLE PATTERN CASTING AND USE OF THE INSTALLATION This invention relates to the precision moulding of consumable patterns for metal alloy parts. It relates primarily to a method in which a mould consisting of a cluster comprising among other things several consumable patterns embedded in a granular material is used.
The technique of precision moulding in which consumable patterns embedded in a granular material are used as a mould (see FR-A-2 647 379 in the name of the applicant) is particularly advantageous in the context of casting in moulds with hollow cavities for casting metal alloy parts. Among its advantages may be mentioned the fact that the pattern, which is consumed by conversion into a gas, has the precise shape of the part being cast without the need for the use of cores.
It makes great accuracy possible, in contrast with a good many conventional casting procedures.
It makes recovery of the granular material, to which no binder is added, a possibility. However, because of the processes inherent in casting, in some cases the number of parts which can be obtained at the same time is limited because a sufficient metal flow has to be ensured when filling a part, particularly if the material forming the pattern has rapid degradation kinetics, this problem being accentuated for parts of large volume, which may then have an adverse effect on the manufacture of the parts, particularly when it is desired to increase the number of parts in a cluster.
The object of this invention is to overcome this limitation and to benefit from the advantages of consumable patterns which can be used to cast parts with great accuracy and to recover the binder-free granular material and cast a large number of parts in one mould at the same time.
This problem is overcome by the method of casting a part in the characterising clause of claim 1 in which the cluster is fed with liquid metal by gravity, causing gasification of the consumable pattern or patterns, with the result that metal alloy parts are obtained on several levels.
The method according to the invention is characterised by an independent metal feed to each of the levels by means of downgates, each one of which only feeds a single level.
Then, depending on the casting conditions (size of the parts, nature of the pattern, head of metal, etc.) the flow to each level can be controlled by correct dimensioning of each of the downgates.
With this flow control it is possible to avoid the conventional defects in the process of casting which uses a consumable pattern, e.g. a defect such as collapse of the granular material, or a cold shut with carbon inclusions.
The ability to ensure a sufficient flow per level in relation to the rate of degradation of the pattern makes it possible both to cast long parts which have to be filled, such as e.g. massive parts, and to increase the number of parts per level.
In order to increase the yield of metal and to fill all the levels in the mould with hot liquid metal simultaneously, the levels are fed by metal from a single casting pouring basin.
The invention also relates to a casting installation for the use of such a method. This installation comprises a mould consisting of patterns of consumable material and feeds thereto forming several levels to obtain cast parts.
The metal feed system comprises gravity downgates each feeding a single level, for rapid filling of a multilevel mould. In particular the consumable patterns may be of polystyrene, as a sufficient flow of metal is obtained.
More specifically, every gravity downgate consists of a hollow revolution member of refractory material.
The installation includes a liquid metal casting pouring basin which together with the gravity downgates forms one assembly of refractory material, and the downgates can be rapidly filled with a sufficient flow of metal with the result that a large number of parts can be obtained per level on several levels for a single melt.
The granular material consists of sand without binder, so that it can be recovered.
A further object of the invention is the use of an installation in accordance with the above description for casting massive metal parts. The parts are of cast iron.
Example embodiments of the invention will now be described with reference to the appended drawing, in which the single figure shows a casting installation according to the invention diagrammatically.
The installation illustrated in the drawing comprises a mould 1 consisting of a cluster 10 of several levels 4, 5 of consumable patterns of expanded material 2 embedded in a granular material 3 without binder. Mould 1 is designed to mould cast iron parts, and for this purpose the installation includes a pouring basin 8 and downgates 6, 7 which feed levels 4, 5 respectively. Level 4 is located higher in the mould than level 5, and each of levels 4, 5 form cluster 10. The granular material is held in a shell 9. It is compacted by vibration.
Each downgate 6, 7 is of a diameter appropriate to the position and composition of level 4, 5 which it feeds so that it is filled with hot metal as rapidly as possible and thus ensures an adequate flow of metal.
Downgate 6 passes through level 4 without contact with patterns 2 in that level. A greater number of levels can be added on the same principle.
Casting pouring basin 8 and downgates 6, 7 are constructed of a fibrous refractory material.
The downgates are hollow frusta of cones with a diameter which decreases downwards.
Levels 4 and 5 take the form of cast parts such as e.g. pipe parts.
During casting the liquid metal is run out from pouring basin 8 into downgates 6, 7, fills these, then gasifies patterns 4 and 5 and fills the space left by the pattern before granular material 3 collapses. After cooling the cluster of parts is separated from granular material 3.
This installation is suitable for casting many massive cast iron parts in a short time with a low metal consumption. For a given number of parts the metal yield is improved in comparison with the technique of casting in a single level.

Claims (10)

1. A method for the precision casting of metal alloy parts with a consumable pattern in which a mould formed of a cluster comprising among other things several consumable patterns embedded in a granular material is used, characterised in that the mould is fed with liquid metal by gravity, causing gasification of the consumable patterns and thus making it possible to obtain metal alloy parts on several levels.
2. A method according to claim 1, characterised in that the metal is fed by downgates, each of which only feed one level.
3. A method according to claim 1 or 2, characterised in that the levels are fed with metal from a single casting pouring basin.
4. A casting installation for implementing the method according to any one of the foregoing claims, characterised in that it comprises a mould formed of patterns of consumable material embedded in a granular material and means for feeding the mould with metal, the consumable pattern or patterns forming several levels in order to obtain cast parts.
5. An installation according to claim 4, characterised in that the feed system consists of gravity downgates, which each feed only a single level.
6. An installation according to claim 4 or 5, characterised in that each gravity downgate is formed of a hollow revolution member of refractory material.
7. An installation in particular according to claim 6, characterised in that a casting pouring basin for liquid metal forms an assembly made of refractory material together with the gravity downgates.
8. An installation according to any one of claims 4 to 7, characterised in that the granular material is sand without binders.
9. Use of an installation according to any one of claims 4 to 8 for casting massive metal parts.
10. Use of an installation according to any one of claims 4 to 9 for casting cast iron parts.
GB9305015A 1992-03-17 1993-03-11 Method and installation for consumable pattern casting and use of the installation Expired - Lifetime GB2265099B (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
FR9203331A FR2688720B1 (en) 1992-03-17 1992-03-17 LOST MODEL MOLDING PROCESS AND INSTALLATION AND USE OF THE INSTALLATION.

Publications (3)

Publication Number Publication Date
GB9305015D0 GB9305015D0 (en) 1993-04-28
GB2265099A true GB2265099A (en) 1993-09-22
GB2265099B GB2265099B (en) 1995-03-01

Family

ID=9427862

Family Applications (1)

Application Number Title Priority Date Filing Date
GB9305015A Expired - Lifetime GB2265099B (en) 1992-03-17 1993-03-11 Method and installation for consumable pattern casting and use of the installation

Country Status (2)

Country Link
FR (1) FR2688720B1 (en)
GB (1) GB2265099B (en)

Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB767218A (en) * 1953-08-27 1957-01-30 Renault Improvements in or relating to moulds for precision casting by the lost wax process
US3868986A (en) * 1974-01-04 1975-03-04 Ford Motor Co Pattern alignment means for use with lost foam molding process
US4240493A (en) * 1979-04-09 1980-12-23 Wilmarth Russell F Shell investment casting process
US4246954A (en) * 1979-02-01 1981-01-27 Wasko Gold Products Corp. Casting tree for tandem mold preparation and method of use thereof
US4340107A (en) * 1978-04-20 1982-07-20 Precision Metalsmiths, Inc. Ceramic shell molding apparatus and methods
US4724889A (en) * 1987-04-27 1988-02-16 Ford Motor Company Degating technique for clustered castings made by ECP
US5058653A (en) * 1986-11-17 1991-10-22 Aluminium Pechiney Process for lost foam casting of metal parts

Family Cites Families (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS55147456A (en) * 1979-05-09 1980-11-17 Komatsu Ltd Production of ball
JPS61199546A (en) * 1985-03-01 1986-09-04 Toyama Chuzo Kk Multi-cavity casting method in full mold casting method

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB767218A (en) * 1953-08-27 1957-01-30 Renault Improvements in or relating to moulds for precision casting by the lost wax process
US3868986A (en) * 1974-01-04 1975-03-04 Ford Motor Co Pattern alignment means for use with lost foam molding process
US4340107A (en) * 1978-04-20 1982-07-20 Precision Metalsmiths, Inc. Ceramic shell molding apparatus and methods
US4246954A (en) * 1979-02-01 1981-01-27 Wasko Gold Products Corp. Casting tree for tandem mold preparation and method of use thereof
US4240493A (en) * 1979-04-09 1980-12-23 Wilmarth Russell F Shell investment casting process
US5058653A (en) * 1986-11-17 1991-10-22 Aluminium Pechiney Process for lost foam casting of metal parts
US4724889A (en) * 1987-04-27 1988-02-16 Ford Motor Company Degating technique for clustered castings made by ECP

Also Published As

Publication number Publication date
GB2265099B (en) 1995-03-01
FR2688720A1 (en) 1993-09-24
GB9305015D0 (en) 1993-04-28
FR2688720B1 (en) 1994-06-17

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Legal Events

Date Code Title Description
730A Proceeding under section 30 patents act 1977
PE20 Patent expired after termination of 20 years

Expiry date: 20130310