MXPA06015124A - Method and apparatus for removal of flashing and blockages from a casting - Google Patents

Abstract

A method of producing a metal casting comprising:pouring a molten metal material into a mold to form a casting having a core aperture;removing the casting from the mold;at least partially clearing the core aperture of the casting;and heat treating the casting.

Description

METHOD AND APPARATUS FOR THE REMOVAL OF CHISPORROTEUM AND BLOCKS FROM A CAST BACKGROUND OF THE INVENTION A traditional casting process for forming castings in metal mold employs one or more types of molds, for example a green sand mold, a sand mold of precision or a steel mold, having the outer elements of a casting or casting in desired mold, such as a cylinder head or engine block, formed on its inner surfaces. A core formed of sand and an appropriate binder material and defining the interior elements of the cast is placed inside the mold or matrix. The core area used to produce contours and interior elements within metal castings should commonly be removed and recovered. Then, the mold or matrix is filled with a molten metal or metal alloy. Then, the casting is removed from the mold or matrix and moved to a treatment furnace for heat treatment, elimination of the sand cores, sand recovery from the sand cores and sometimes aging. Heat treatment and aging are processes that condition the metal or metal alloy to obtain various desired properties desired for a given application. Once the casting is formed, several stages Differently different should be made in general for the purpose of heat treating the metal casting and recovering the sand from the sand core. First, a portion of the sand core is separated from the cast using one or more techniques. For example, the sand can be lowered from the cast or the cast can be physically stirred or vibrated to break the sand core and remove the sand. Additionally, where the molds include one or more holes to access the cores, the holes that are blocked must be cleared. After or during the sand which is removed from the casting, the heat treatment and aging of the casting are generally carried out in subsequent stages. The casting is commonly heat treated if it is desirable, among other things, to offer or reinforce the casting or relieve internal efforts in casting. Although many advances have been made in the metal casting industry, there is still a need for an improved process to remove cores and residual sand from casting. Various objects, elements and advantages of the present invention will become apparent to those skilled in the art after a review of the following detailed description when taken in conjunction with the accompanying figures.

BRIEF DESCRIPTION OF THE FIGURES Figure 1 illustrates an exemplary metal casting process in accordance with various aspects of the present invention; Figure 2 illustrates another exemplary metal casting process in accordance with various aspects of the present invention, and Figure 3 illustrates yet another exemplary metal casting process in accordance with various aspects of the present invention.

DETAILED DESCRIPTION Several aspects of the present invention are generally concerned with casting processes. In one aspect, the present invention is concerned with various methods and apparatus for improving sizzle removal and other blockages to gain access to a core within a cast. Metal casting processes in general are known to those skilled in the art and will be described only briefly for reference purposes. It will be understood that the present invention can be used in any type of casting process, in which metal casting processes are included to form castings of aluminum, iron, steel and / or other types of castings of metal and metal alloy. Thus, the present invention is not limited to use with a particular casting process or a type or types of metal particles or metal alloys. Figure 1 generally illustrates an exemplary metallurgical casting process 10 according to various aspects of the present invention. A metal or molten metal alloy M is commonly poured into a die or mold 15 in a pouring or casting station 20 to form a casting., such as a cylinder head, motor block or similar casting part. The mold generally includes a plurality of walls that define an internal cavity within which the molten metal is received. The cavity is formed with a relief pattern that forms the internal elements of the castings. A pouring orifice is generally formed in the outer wall, commonly in the upper part of the mold and communicates with the internal cavity to allow the molten metal to be poured or otherwise introduced into the mold. A core formed of sand and an organic binder, such as a phenolic resin or any other suitable binder material, is received or placed inside a mold to create hollow cavities, casting details and / or core impressions within the casting. The casting can include one or more openings in the core to provide access to the core. . Any suitable mold or matrix can be used with various aspects of the present invention. For example, the mold can be a permanent mold or matrix (in which they include high and low pressure castings), commonly formed from a metal such as steel, cast iron or other suitable material. Such a mold can have a clam-shell design for ease of opening and removal of the casting thereof. Alternatively, the mold can be a "precision sand mold" or "green sand mold", which is generally formed from a sand material, such as silica sand, zirconium sand or other suitable material mixed with a binder such as a phenolic resin or other suitable binder. Similarly, the core can be formed of a sand material and a binder, for example a phenolic resin, phenolic urethane "cold box" binder or any other suitable binder material. Alternatively, the mold may be a semi-permanent sand mold, which commonly has an outer mold wall formed of sand and a binder material, a metal such as steel or a combination of both types of materials. It will be understood that the term "mold" will be used hereinafter to refer generally to all mold types as discussed above, which include permanent or metal matrices, semi-permanent sand mold type molds and precision and other metal casting molds, except where a mold of a particular type is specified. A source or heating element (not shown), such as a heated air fan or other electric heater mechanism or fired by appropriate gas or fluidized bed, may be provided adjacent to the pour station to pre-heat the mold. A pre-heating process can be used to maintain the temperature of the molten metal and / or the casting at an elevated temperature, for example at least about the heat treatment temperature, to minimize heat loss and improve the efficiency of the process . Additionally, in some instances, pre-heating of the mold can initiate the process of thermal treatment of the casting within the mold. The mold can be heated to any appropriate temperature as necessary or desired for the particular metal or alloy used to form the cast. For example, for aluminum, the mold can be pre-heated to a temperature of about 400 ° C to about 600 ° C. Other pre-heating temperatures for various metal alloys and other metals are known to those skilled in the art and include a wide temperature range from about 300 ° C to about 1200 ° C. Other preheating temperatures are contemplated herein. Depending on the aggregate and binder used to make the mold and / or core, a lower pre-heating temperature can be used to prevent the deterioration of the mold and core during pouring and solidification. In such cases and where the metal process temperature must be higher, an appropriate temperature control method, such as induction heating or other processes known in the art, can be used to obtain the desired process results. Alternatively, the mold can be provided with a source or internal heating element. For example, a permanent type metal matrix may include one or more cavities or passages adjacent to the casting through which a controlled heated fluid medium, such as water or a thermal oil, may be received and / or circulated. After this, fluid media having a lower temperature, for example of about 250 ° C or about 300 ° C, can be introduced or circulated through the mold to cool the castings and cause the castings to solidify at least partially. A higher temperature thermal oil, for example, heated to a temperature of about 500 ° C to about 550 ° C, can then be introduced and / or circulated through the die to stop casting cooling, and in some Instances, to raise the temperature of the castings back to a rinsing temperature for the thermal treatment of the castings. After the molten metal or metallic alloy The casting has been poured into the mold and has at least partially solidified to a casting, the mold with the casting therein is removed from the pouring station by a transfer mechanism and transferred to a charging station (not shown). The transfer mechanism may include a transfer robot (not shown), a winch or another type of conventionally known transfer mechanism. At the loading station, the casting can be removed from the mold and loaded to a saddle or basket including positioning devices to maintain the casting in a graduated position relative to the processing equipment and other castings. By doing this, it can be ensured that the casting is oriented as necessary to effect the removal of the core and / or cleaning, as will be described later herein. Returning to Figure 1, according to one aspect of the present invention, casting is then transferred to a core opening station 35. In the core opening station 35, the openings or holes in the core are at least partially cleared to dislodge, separate and / or remove (collectively "clear" or "remove") blockages and provide access to the core for subsequent processing . Additionally, all or a portion of the core can be removed during the core opening process. Although the core openings can be cleared at various points throughout the casting process metal, there are several advantages to clear the core openings before core removal and / or heat treatment. For example, by clearing blocked core openings, the demixing process is improved, thereby resulting in a substantially reduced heat treatment time. Additionally, the cooling process (discussed later herein) can be improved, thereby resulting in improved metal quality and some instances, a decrease in cooling time or overall process time. Thus, the reduction in time required for demixing and heat treatment may allow the process to be carried out without the need for conventional glue forming methods of casting charges to baskets, trays or other multiple casting carriers. Instead of this, means of transportation of direct contact, such as a chain, roller, beam-rocker or other similar transportation mechanism can be used. The core openings can be cleared using any of numerous appropriate techniques. In one aspect, the core openings are cleared using a "punching" system that physically hits the opening lock. In another aspect, the openings of the core are cleared using a "deburring" system that penetrates and "cuts" the locks of the openings. Such systems of Die cutting and deburring can use a physical or mechanical cutter, such as a laser, milling machine, drill, drilling device, saw or die cutting press system with perforating / deburking molds to physically cut or otherwise penetrate the blockage. The deburring device can also be used to eliminate the feed gates, and / or risers created during the casting formation. In yet another aspect, the blockage can be eliminated by shaking or vibrating the casting. In yet another aspect, blocking can be eliminated by crashing the block with sound. In yet a further aspect, the blocking can be eliminated by peening or by striking a heated or unheated fluid or particulate media, for example water, oil, air or sand. Various nozzles, shock pressures, volumes and temperatures of the fluids can be used as necessary to obtain the desired results and are contemplated herein. Any size and arrangement of nozzles can be used as desired. In one aspect, each nozzle can have a diameter of about 0.32 cm (0.125 inch) to about 2.54 centimeters (1.00 inch), for example about 0.635 cm (0.25 inch). Also, the media can be supplied at any appropriate flow rate and pressure and in one aspect, can be supplied to a flow rate of about 0.25 m3 / minute (10 feet3 / minute) to about 36.8 m3 / minute (1300 feet3 / minute) at a pressure of about 0.35 to about 10.5 kg / cm2 (5 to about 150 pounds / inch2). Any such device can be attached to a robotic mechanism adapted to traverse the casting to clear the openings in the core. Where such a device is used, the casting can be kept stationary using clamps or other securing devices. In some instances, "pear bolts", rods similar elements are used to push, propel or otherwise assist or promote the removal of casting from your mold. If desired, such elements can be placed in such a way that one or more selected elements will engage and pierce the blocked openings as casting is driven from its mold. Such elements may include devices for checking the temperature of the casting when the elements are coupled thereto. Optionally, the sand removed from the core opening process and any other process described herein or contemplated herein may then be purified. The purification process can include burning the binder that covers the sand, abrading the sand, rubbing the sand and passing portions of the sand through the sand. sieves. Some of the sand can be subjected to multiple recovery processes until sufficiently pure sand is obtained. Before, during and after the core opening process, the casting temperature can be maintained at or above a process control temperature. It has been found that, as the cast metal is cooled, it reaches a temperature or temperature range referred to herein as the "process control temperature" or "critical process temperature", below which the The time required to both raise the castings to heat treatment temperature and effect the heat treatment is significantly increased. It will be understood by those skilled in the art that the process control temperature for the castings that are processed by the present invention will vary depending on the metal and / or particular metal alloys that are used for the castings, the size and shape of the castings and numerous other factors. In one aspect, the process control temperature may be about 400 ° C for some alloys or metals. In another aspect, the process control temperature may be from about 400 ° C to about 600 ° C. In another aspect, the process control temperature may be from about 600 ° to about 800 ° C. In yet another aspect, the process control temperature may be about 800 ° C to about 1100 ° C. In yet another aspect, the process control temperature may be from about 1000 ° C to about 1300 ° C for some alloys or metals, for example iron. In a particular example, an aluminum / copper alloy can have a process control temperature of from about 400 ° C to about 470 ° C. In this example, the process control temperature is generally lower than the heat treatment temperature of the solution for most copper alloys, which is commonly around 475 ° C to about 495 ° C. While particular examples are provided herein, it will be understood that the process control temperature can be any temperature, depending on the metal and / or particular metal alloys that are used for casting, the size and shape of the cast and numerous other factors. When the cast metal is within the desired process control temperature range, the cast will commonly be cooled sufficiently to solidify as desired. However, if the cast metal is allowed to cool below its process control temperature, it has been found that the casting may need to be heated for at least about 4 additional minutes per minute that the cast metal is cooled below. of the process control temperature to reach the treatment temperature desired thermal, for example from about 475 ° C to about 495 ° C for aluminum / copper alloys or from about 510 ° C to about 570 ° C for aluminum / magnesium alloys. Thus, if the cast is cooled below its process control temperature even for a short time, the time required to thermally treat the cast properly and completely can be increased significantly. In addition, it must be recognized that in a batching system, where several castings are processed through the heat treatment station in a single batch, the heat treatment time for the entire batch of casting is generally based on time of heat treatment required for the cast (s) with the lowest temperature in the batch. As a result, if one of the castings in the batch is processed, it has been cooled to a temperature lower than its process control temperature, for example, for approximately 10 minutes, commonly the entire batch will need to be heat treated, for example at least 40 additional minutes to ensure that all castings are heat treated properly and completely. The process control temperature can be maintained in a process control temperature station (not shown) that can be separated from or integral with other process components, such as the core opening station. The process control temperature station can include various combinations of heating and temperature control element. In one aspect, the process control temperature station includes a radiant chamber with a series of heat sources mounted therein, for example, along the walls and / or ceiling of the chamber. Commonly, multiple heat sources can be used and can include one or more several different types of heat sources or heating elements, which include sources of radiant heating, such as infrared, electromagnetic and inductive power sources, sources Conductive type heat, convective and direct shock type heat sources, such as gas-heated burner tubes that introduce a gas flame to the chamber. In addition, the side walls and roof of the radiant chamber can be formed of or coated with a high temperature radiant material, such as a metal, metal film or similar material, ceramic material or composite material capable of radiating heat. The radiant coating generally forms a non-adherent surface on the walls and ceilings. As the walls and ceilings of the chamber are heated, the walls and ceiling tend to radiate heat towards the casting and at the same time, the surfaces are generally heated to a temperature sufficient to burn waste gases and / or waste such as soot, etc., of the combustion of the binders in the sand molds and / or cores to prevent collection and accumulation of the same on the walls and ceiling of the camera. In one aspect, the process temperature control station can function as a retention area in front of the heat treatment station or chamber. The casting temperature can be maintained or stopped at or above the process control temperature, but equal to or less than a desired heat treatment temperature, to allow the casting to fully solidify while awaiting introduction to the station. heat treatment. Thus, the system allows the piping line or lines to be put into operation at a faster or more efficient speed without the casting having to settle in a row or line waiting to be fed to the thermal treatment station while it is exposed to the environment, resulting in the casting being cooled below its process control temperature. Various aspects of the present invention include systems for verifying casting temperature to ensure that casting is maintained substantially at or above the process control temperature. For example, thermocouples or other similar temperature sensing devices or systems may be placed on or adjacent to the casting or at spaced locations along the travel path of the casting from the pouring station to a heat treatment furnace to provide a substantially check keep going. Alternatively, periodic verification at certain intervals to be frequent enough can be used. Such devices may be in communication with a heat source, such that the temperature sensing or measuring device and the heat source can cooperate to keep the casting temperature substantially at or above the process control temperature for the metal of the casting. It will be understood that the casting temperature can be measured at a particular location on or in the cast, it can be an average temperature calculated by measuring the temperature in a plurality of sites on or in the casting or it can be measured in any other way as necessary or desired for a particular application. Thus, for example, the temperature of the casting can be measured at multiple sites on or in the casting and an overall temperature value can be calculated or determined to be the lowest temperature detected, the highest temperature detected, the average temperature detected, the average temperature detected or any combination or variation thereof. Additionally, prior to entering the heat treatment furnace, the casting can pass through an inlet or reject zone (not shown), where the temperature of each casting is checked to determine if the cast has been cooled to an extension that would require a excessive amount of energy to raise the temperature to the temperature of heat treatment. The entrance zone can be included in the process control temperature station or it can be a separate zone. The casting temperature can be verified by any suitable temperature sensing or measuring device, such as a thermocouple, to determine if the casting temperature has reached or fallen below a pre-set or pre-set reject temperature. In one aspect, the predefined rejection temperature can be a temperature (e.g., from about 10 ° C to about 20 ° C) less than the process control temperature for the cast metal. In another aspect, the predefined rejection temperature may be a temperature (e.g., from about 10 ° C to about 20 ° C) less than the heat treatment temperature of the heat treatment oven or heater. If the casting has cooled to a temperature equal to or lower than the predefined temperature, the control system may send a reject signal to a transfer or removal mechanism. In response to the detection of a defective condition or defect signal, the subject cast may be identified for further evaluation or may be removed from the transfer line. Casting may be separated by any suitable mechanism or device including, but not limited to, a robotic arm or other device Automated or casting can be manually removed by an operator. As with the above, it will be understood that the casting temperature can be measured at a particular location or in the casting, it can be an average temperature calculated by measuring the temperature at a plurality of sites in or on the casting can be measured from any other as necessary or desired for a particular application. Thus, for example, the casting temperature can be measured at multiple sites on or in the casting and a global value can be calculated or determined to be the lowest temperature detected, the highest temperature detected, the average temperature detected, the average temperature detected or any combination or variation thereof. Before or after completion of the core opening process, casting can be transferred using any suitable device 40 individually or in batches to a thermal treatment station 45 for heat treatment, sand core breakage and / or sand mold and removal and in some instances, for the recovery of sand. The heat treatment can be used to strengthen or harden the cast or to relieve internal stresses. The casting is heated to an appropriate temperature, maintained at that temperature for a sufficiently long time to allow a certain constituent to enter into solid solution and then cooled quickly to keep that constituent in solution. The heat treatment station generally includes a heat treatment furnace (not shown), commonly a gas-heated furnace or heated by commonly available means and generally includes a series of treatment zones or chambers for the heat treatment of each casting and removal and recovery of sand material from sand cores. Such heat treatment zones may include various types of heating environments such as conduction, which include the use of fluidized beds and convection or other commercially viable systems known in the art, such as using heated air flows. The number of treatment zones may vary as necessary or required for a particular application to remove the sand cores. The residence time within the heat treatment station or each zone thereof may be relatively to the time necessary for heat treatment of the casting to a desired level. It is also possible to partially age the casting within the heat treatment station if desired. The heat treatment station may include several sources of heat in any appropriate combination. Heat sources include convection heat sources such as fans or nozzles that apply heated media such as air or other fluids, conduction heat sources such as a fluidized bed, induction heat sources, radiant and / or other types of heat sources can be mounted within the walls and / or roof of the furnace chamber to provide heat and an optional air flow around the cast in various grades and amounts to heat the cast to the appropriate heat treatment temperatures. Such desired heat treatment temperatures and heat treatment times will vary according to the type of metal or metal alloy from which the cast is formed, as will be known to those skilled in the art. Examples of various heat treatment furnaces that may be suitable for use with the present invention include those described in U.S. Patent Nos. 5,294,994; 5,565,046 and 5,738,162, the disclosures of which are hereby incorporated by reference. A further example of an oven or heat treatment station for use with the present invention is illustrated and disclosed in U.S. Patent No. 6,217,317 and U.S. Patent Application Serial No. 09 / 665,354, filed September 9, 2000, and 10 / 051,666, filed on January 19, 2002, the disclosures of which are also incorporated herein by reference in their entirety. Such heat treatment stations or furnaces may include elements for recovering the sand of the cores and / or molds dislodged during the heat treatment of the casting. According to another aspect of the present invention illustrated in Figure 1, after the heat treatment is complete, the casting is transferred from the heat treatment station 45 to a cleaning station 50 via a robot or other automated means 55. The The casting is placed in a vestibule having nozzles 60, placed around the periphery of the casting. One or more nozzles can be placed in direct alignment with the open holes. Additionally, one or more nozzles can be inserted into the open holes. The nozzles then direct a jet of air, water, oil or other means to the holes to assist with the removal of the cores. During the cleaning process, some areas of the casting may be slightly cooled; however, any change in temperature is probably minimal. After the cleaning process is complete, the casting can be transferred to an aging furnace 65. According to another aspect of the present invention, illustrated in Figure 2, the casting can be transferred to a cooling station 70 after cleaning 50. The cooling process provides a high volume / pressure of fluid media (water, air, steam, oil, etc.) to the casting via openings or otherwise. The cooling process can use a cooling tank or container filled with a cooling fluid, such as water or other material of known means, in which each casting or batch of castings are submerged for cooling and quenching. The cooling tank or tank is designed to accommodate the size and type of casting that is formed, the specific heat of the metal or metal alloy, and the temperatures at which each cast has been heated. The shutdown time and temperature can be controlled to obtain the desired mechanical and physical properties of the casting desired. In some instances, the shutdown station can be maintained at a temperature of about 49 ° C (120 ° F) to about 93 ° C (200 ° F). As before, casting can then be transferred to an aging furnace immediately or at a later time depending on the process required for the specific component. According to another aspect of the present invention illustrated in Figure 3, after the solution heat treatment is complete, each pour is transferred from the heat treatment station 45 to a shut down station 70 for further cleaning and processing. The shutdown station commonly includes a quench tank having a cooling fluid such as water or other known refrigerant or may comprise a chamber having a series of nozzles that apply cooling fluids such as air, water or similar cooling means. As described above, the The quenching process removes a substantial portion of the inner cores by providing a high volume of air, water, steam and / or oil to the casting to reduce the casting temperature to a desired final temperature. Frequently, the extinguishing means accumulate traces of sand from the castings. The sand is then re-deposited on the casting. Thus, casting after this can be transferred to a cleaning station 50 for further cleaning and processing. As described above, the cleaning process subjects the casting to a variable volume, pressure and temperature of a stream of air, water, oil or steam media. When air is used to clean the cast, the cleaning process can also turn off the casting. After the cleaning of the casting, the casting can then be placed in an aging furnace 60 if desired. Thus, it will be readily understood by those skilled in the art that, in view of the above detailed description of the invention, the present invention is susceptible of wide utility and application. Many adaptations of the present invention other than those described herein, as well as many variations, modifications and equivalent arrangements will be apparent from or reasonably suggested by the present invention and the foregoing detailed description thereof, without departing from the substance or scope of the invention. the present invention.

While the present invention is described herein in detail in relation to specific aspects, it will be understood that this detailed description is only illustrative and exemplary of the present invention and is made solely for purposes of providing full disclosure and enabling of this invention. The detailed description summarized herein is not intended or will be construed to limit the present invention or to otherwise exclude any such other embodiments, adaptations, variations, modifications and equivalent arrangements of the present invention, the present invention is limited only by the claims attached to this, and the equivalents thereof.

Claims (20)

1. CLAIMS 1. A process for producing metal casting, characterized in that it comprises: pouring a molten metal material into a mold to form a cast having a core opening; remove the cast from the mold; clear the opening of the casting core; and heat treating the casting. The method according to claim 1, characterized in that it further comprises maintaining the casting temperature at or above a process control temperature for the metal. The method according to claim 1, characterized in that it further comprises maintaining the casting temperature at or above a process control temperature for the metal until the casting is heat treated. 4. The method according to claim 1, characterized in that it further comprises applying energy to the casting to stop the cooling of the casting and to at least partially heat-treat the casting. The method according to claim 1, characterized in that it further comprises preheating the mold to a temperature of at least about the heat treatment temperature for the metal. 6. The method according to claim 5, characterized in that it further comprises pouring the molten metal into the mold as long as the mold is at the preheated temperature. The method according to claim 1, characterized in that the clearance of the core opening comprises punching, milling, drilling, laser application or cutting of a blockage within the core opening or shot blasting of fluid means in the lock inside. of the core opening. The method according to claim 1, characterized in that the clearance of the core opening comprises penetrating a lock in the opening of the core with a driving element as the casting is removed from the mold. The method according to claim 10, characterized in that it further comprises checking the temperature of the casting using a temperature measuring device in communication with the driving element. A system for processing a metal casting, having a core opening, characterized in that it comprises: a pouring station for forming the casting; a core opening station comprising a core opening device for clearing a blockage of the opening of the nucleus; a thermal treatment station downstream of the core opening station; at least one process temperature control station comprising a power source for maintaining the cast at a temperature of or above a process control temperature for the metal between the pour station and the heat treatment station. The system according to claim 10, characterized in that it further comprises a heat source for preheating the mold to a temperature of at least about the heat treatment temperature for the metal. The system according to claim 10, characterized in that the core opening device comprises a punching, milling, drilling, laser, sheet or blasting nozzle. The system according to claim 10, characterized in that the core opening device comprises a drive element. The system according to claim 10, characterized in that the driving element includes a temperature measuring device. 15. The system according to claim 10, characterized in that the thermal treatment station It comprises a reject zone for casting. 16. The system according to claim 15, characterized in that the casting reject zone comprises: a casting temperature measuring device; and a transfer mechanism in communication with the temperature measurement device, the transfer mechanism is adapted to remove the casting before entry into the furnace after detection of a reject temperature by the temperature measuring device. The system according to claim 10, characterized in that the process control temperature station further comprises a temperature sensing device in communication with the heat source of the power source and the transfer mechanism. The system according to claim 17, characterized in that the process control temperature station further comprises a controller in communication with the heat source temperature sensing device, the controller controls the amount of energy applied to the casting. 19. A system for processing a metal casting, characterized in that it comprises: a first heat source for preheating a mold at a temperature of at least about the heat treatment temperature for a molten metal to be poured; a pouring station for pouring the molten metal into the preheated mold; a first process control temperature station downstream of the pour station, the first process control temperature station includes a second heat source to keep the metal at or above a process control temperature as the metal at least partially solidifies and forms a cast having a core opening; a casting removal station to remove the cast from the mold; a core opening station comprising a core opening device for clearing a blockage of the core opening; a second process control temperature station integral with the core opening station, the second process control temperature station includes a second heat source to keep the metal at or above a custom process control temperature that the opening of the nucleus is clear; and a thermal treatment station. 20. The system in accordance with the claim 19, characterized in that the core opening device comprises a die-cutting, milling, drilling, laser, blade, blasting nozzle or driving element.