US3395747A

US3395747A - Casting method

Info

Publication number: US3395747A
Application number: US221115A
Authority: US
Inventors: Earl A Thompson
Original assignee: Individual
Current assignee: Individual
Priority date: 1962-09-04
Filing date: 1962-09-04
Publication date: 1968-08-06
Anticipated expiration: 1985-08-06

Description

Aug. 6, 1968 E. A. THOMPSON CAST I NG METHOD 6 Sheets-Sheet 1 INVENTOR.

EARL A. THOMPSON i zw AGENT 1968 E. A. THOMPSON 3,395,747

CASTING METHOD Filed Sept. 4, 1962 6 Sheets-Sheet 3 dm/llllg g INVENTOR.

EARL A. THOMPSON AGENT E. A. THOMPSON 3,395,747

CASTING METHOD 1962 6 Sheets-Sheet 5 Aug. 6, 1968 Filed Sept. 4

INVENTOR. gKARL A. THOMPSON fi,

Qm Nb AGENT 6, 1958 E. A THOMPSON 3,395,747

CAST ING METHOD Filed Sept. 4, 1962 6 Sheets-Sheet 6 INVENTOR.

gARL A. THOMPSON AGENT United States Patent m 3,395,747 CASTING METHOD Earl A. Thompson, 1300 Hilton Road, Ferndale, Mich. 48220 Filed Sept. 4, 1962, Ser. No. 221,115 21 Claims. (Cl. 164-95) This invention relates to composite casting, and more particularly to method and apparatus for continuously casting improved multi-metal articles, such as exhaust valves for the combustion chambers of internal combustion engines.

While the method and apparatus of this invention are capable of producing various products having particular, but differing metallurgical characteristics in separate portions of the article, exhaust valves for combustion engines aptly illustrate one such product.

Valves currently in use are subject to extremely ad- Verse operating conditions. The head must function in temperatures above 1500 F. in certain modern automotive engines utilizing high octane fuels, and it must resist corrosion from the combustion products of such leaded fuels. It must also have high impact strength under these unfavorable conditions to withstand abrupt, high seating loads. The bevelled or conical seating perimeter of the valve head, on the other hand, must be even further resistant to corrosion and metal to metal wear, but need not have the low cost, high strength and toughness characteristics of the flared head itself. The valve stem, moreover, while operating at somewhat lower temperatures than the seating area, must have additional resistance to abrasion and wear in the valve guide and particularly from the actuating cam or rocker arm.

The valve art is crowded with various proposals to meet these needs, none of which have provided ultimate solutions in the practical sense. Attainment of all the desired exhaust valve properties in a single alloy appears to be at best a prohibitively expensive compromise.

Forming the parts of the valve of separate alloys parts welded together also is expensive, and the weld joints often fall short of the desired standard. For instance, in the past an upset or extruded austenitic steel head, which has the desired performance and cost qualities, has had welded or puddled therearound a facing of expensive cobalt-base metal to form the seat. But the different coefiicients of thermal expansion of these two metals obviously creates an unbalance of expansion forces at different temperatures acting on the joint between the two; and, the weld represents an interruption extendig across the radial paths along which heat is conducted away from the hot center of the head to the seating area. Additionally, welding a carbon steel tip of the hardenable martensitic type to the end of the austenitic steel valve stem represents a further expensive processing step.

Accordingly, it is an object of the present invention to form improved exhaust valves inexpensively by casting suitable separate metals sequentially into the ap propriate places in a mold to form an autogenously united cast valve exhibiting the desired qualities in each portion thereof without the disadvantages of welded joints.

Another object of this invention is to provide 'an improved casting method for continuously producing multimetal articles which utilizes forces other than gravity to locate molten metal in the desired portion of the mold to form one portion of the article and also utilizes gravity to locate other molten metal in the mold to form another portion of the same article.

Another object of this invention is to provide an improved continuous cast-ing apparatus including means for imparting centrifugal force to metal in a mold.

Another object of this invention is to provide, in combination with a continuous centrifugal casting machine 3,395,747 Patented Aug. 6, 1968 for composite casting, a 'mechanico-hydraulic motivator of the rotary cam and liquid column type.

Another object of this invention is to provide a cast engine valve of improved metallurgical quality.

Further objects and advantages of the present invention will be apparent from the following detailed description, with reference to the accompanying drawings in which like reference characters refer to the same parts throughout the several views, and in which:

FIGURE 1 is a general plan view showing the major components of the casting machine of this invention;

FIGURE 2 is a fragmentary sectional elevational view showing the index table and a pouring station of the machine;

FIGURE 3 is a sectional view on line 33 of FIGURE 2 showing details of the indexing mechanism;

FIGURE 4 is an enlarged plan view with parts broken away showing the general scheme of the transfer arm loading means for fresh molds;

FIGURE 5 is a sectional view showing the mechanism for swinging and elevating a transfer arm;

FIGURE 6 is a sectional view on line 66 of FIG- URE 5 showing the fluid motor for swinging a transfer arm;

FIGURE 7 is a plan view showing the general scheme of the transfer arm unloading means for filled molds;

FIGURE 8 is an enlarged sectional view of the compensating arrangement for the metal metering valve of a pouring station;

FIGURE 9 is an enlarged sectional view of a spindled mold holder on the index table periphery;

FIGURE 10a is a schematic view of the controls for the mechanico-hydraulic motivator for the machine of this invention;

FIGURE 10b is a schematic view of the actuating portion of the mechanico-hydraulic motivator connected with the fluid motors on the casting machine;

FIGURES ll, 12 and 13 are fragmentary sectional views through a mold illustrating different steps in the casting process;

FIGURE 14 is an elevational view partly in section of a product cast according to this invention; and

FIGURE 15 is a view of a product such as an internal combustion engine valve in its functional environment.

Referring to FIGURES 1 through 10b, the preferred embodiment of a composite centrifugal casting machine is disclosed. Generally, an index member such as an intermittently shiftable rotary table 10 moves mold holders 12 spaced around its periphery past a series of stations including a fresh mold loading station 14, a mold holder rotating station 16, a first metal pouring station 18, a second such station 20-, a mold holder slow down station 22, a third metal pouring station 24, and a filled mold unloading station 26.

The shiftable table member 10 is supported on a base or pedestal 30 located on a foundry floor 32, see FIG- URE 2. Beneath the table 10, an inner thrust bearing race 34 may be secured by fasteners 36, and the inner portion of the race may further include a ring of internal gear teeth 38. An outer bearing race 40 may be secured in a horizontal plane to the base 30 by fasteners 42 in a position to retain ball bearings 44 and thus support the table 10 for rotary motion.

Drive mechanism for the table may include a pinion 46 meshing with the gear teeth 38 of the table and driven by a vertical shaft 48 which is journalled in and axially shiftable through suitable bearings 50 in the machine base. Pinion teeth 52 integral with the shaft are engaged by the teeth of a sliding rack 54. A pair of U-cup sealed piston faces 56 (FIG. 3) on either end of the rack 54 reciprocate in aligned cylinders 58 to shift the rack to and fro between adjustable limit stops 60. Pressurized fluid admitted through a connection 62 at one end of the cylinder arrangement rotates the drive pinion 48 in the resetting direction, and pulsator fluid admitted to the other end through a connection 64 rotates the drive pinion to index the table member 10.

The lower end of the pinion shaft 48 has a swivel connection 66 with the upper end of the rod 68 of a piston 70 vertically slidable in a cylinder 72 in the machine base. Pressurized fluid admitted to the cylinder 72 through a connection 74 biases the shaft downwardly to disengage the drive pinion 46 from the table gear teeth 38, and hydraulic fluid admitted through a connection 76- elevates the drive pinion to engage the teeth 38. It will be noted that the pinion teeth 52 are axially elongated so as to retain their meshing engagement with the rack 54 as the shaft 48 is raised and lowered.

When the table 10 has been indexed through a small predetermined number of degrees of angular motion and the drive pinion 46 is lowered so that the rack 54 may be reset, a locking and locating device may become operative. Such a device may include a gear tooth 78 secured to the rod 80 of a piston 82 axially shiftable in a cylinder 84. Hydraulic fluid admitted to the cylinder 84 through a connection 86 retracts the piston 82 and allows rotary motion of the table 10. Hydraulic fluid admitted to the other end of the cylinder 84 through a connection '88 shifts the piston 82 to engage the gear tooth 78 with a tooth of the ring of gear teeth 38 on the table. This accurately locates and locks the table in position while metal is being poured into one of the molds, and while the drive gear 46 is lowered for resetting.

For loading and unloading the molds to and from the holders 12 on the shiftable member 10, a. pair of transfer arms may be provided (FIG. 1), one at the first station 14 ahead of the plurality of pouring stations and one at the final station 26 following the series of pouring stations. The loading means 90 at the first station is illustrated in FIGURE 4; the unloading means 92 at the final station is illustrated in FIGURE 7. Both means may comprise horizontally swinging transfer arms with a gripper at the outer end and an elevating mechanism at the pivot, and they may be identical in structure differing only in operational timing of moving parts-- thus detailed description of one will suffice to disclose the structure of both.

As can be seen in FIGURES 4-6, such a transfer arm may comprise a generally horizontally extending swinging body member 94 fixed at one end on a vertical pivot shaft 96 which is journalled in and axially shiftable through suitable bearings 98 in the machine base (FIG. Pinion teeth 100 integral with the pivot shaft are engaged by the teeth of a slida'ble rack 102. A pair of U-cup sealed piston faces 104 (FIG. 6) on either end of the rack 102 reciprocate in aligned cylinders 106 to shift the rack to and fro between adjustable limit stops 108. Pressurized fluid admitted through a connection 110 swings the arm away from the index member 10, and pulsator fluid admitted through a connection 112 swings the arm in the opposite direction toward the table as can be understood.

The lower end of the arm pivot shaft 9 6 has a swivel connection 114 (FIG. 5) with the upper end of the rod 116 of a piston 118 vertically reciprocable in a cylinder 120 in the machine base. Pressurized fluid admitted to the cylinder 120 through a connection 122 biases the shaft downwardly on the machine base, and hydraulic medium admitted through a connection 124 elevates the shaft 96 and consequently lifts the arm 94 bodily upward at predetermined distance. It will be noted that the pinion teeth 100 are axially elongated so as to retain their meshing engagement with the rack 102 as the arm is raised and lowered.

On the outer end of such a transfer arm, a pair f gripper jaws 126 are shiftable in opposition to one another along the arm axis. They shift in unison by means of a common double rack and central pinion assembly 128 (FIG. 4) housed in the arm itself. Double piston-cylinder arrangement 130 in the arm serves to close the jaws when subjected to hydraulic pressure through a connection 132, and open the jaws when subjected to hydraulic pressure through a connection 134.

The transfer arms may be operated by the mechanicohydraulic motivator (explained in detail below) in the following fashion. First, the jaws of the loading arm 90 close to grip a fresh shell mold at the supply station 14 continuously replenished with fresh molds by suitable means such as an endless belt 136. Then the loading arm israised to lift the mold clear of guide rails 138 at the supply station so that it may swing clockwise (FIG- URE 4) to position the gripped mold over a holder 12 presented at the loading station. Lowering of the arm and subsequent opening of the jaws serves to deposit the mold on the index member, which may begin its next indexing movement prior to the arm swinging counter-clockwise back to the mold supply station.

The unloading arm 92 (FIGURE 7) may move through a somewhat different cycle. As a filled mold is indexed by the member 10 to the unloading station 26, the jaws of the unloading arm close to grip the mold, crunching through any loose sand if necessary and engaging the cooling casting. Then the arm will raise bodily, lifting the casting clear of the fixture 12 free to swing counter-clockwise to a position above a shaker screen 140. At this point, the jaws may open and allow the workpiece to drop to the screen which will vibrate it away toward a subsequent operation, freeing the casting of loose sand as it goes. The unloading arm may then be lowered as it is returned in a clockwise direction to receive the next filled shell mold. Thus, the loading and unloading means, while identical in structure, follow different programs to render the composite casting apparatus of this invention entirely automatic and well suited to modern high volume mass production requirements.

Between the loading station 14 and the first metal pouring station 18, a mold rotating station 16 may include below the table edge a drive means such as an electric motor 142 connected to spin a fiber drive wheel 144. The motor 142 may be mounted on a support 146 pivoted to the machine base at 148 to swing the drive wheel 144 toward and from the circular path of the mold holders 12. A fluid motor 150 may be connected therewith to control such shifting in timed relation with movement of the table 10.

The trio of

metal pouring stations

18, 20 and 24 may each include a bottom pour induction heated container, illustrated in the upper portion of FIGURE 2. T he pouring stations may be comprised of similar elements, thus description of station 18 will provide a disclosure of all; structural elements of the pouring station 20 will be designated by similar reference numerals with the addition of a prime mark, and structural elements of the pouring station 24 will be designated by similar reference numerals with the addition of a double prime mark.

Station 18 may include a casting furnace 152 comprising an induction heating coil 154 concentrically surrounding a container 156 of generally upright cylindrical configuration and may be separated therefrom by a centering and insulating layer of packed casting sand 158. The container 156 and heating arrangement 154 may be sup ported upon suitable slabs of refractory or ceramic material located upon a framework 160, and may be separately replaceable as a unit on the framework to ex-- I change one such furnace for another of different characteristics required for casting, for instance, of a different article. A split disc-shaped cover 162 conserves the continuously generated anti-oxide atmosphere.

In" addition to removably locating each casting furnace relative to the table 10, the framework 160 further supports actuating mechanism for valving arrangements constructed to meter predetermined small amounts of molten metal from the casting furnaces to a mold positioned on the table. Such a valving mechanism may comprise an elongated shiftable valve member 164 of refractory material having a semi-spherical bottom end portion 166 extending down into the container 156, and an upper portion 168 extending above the container 156. An actuating lever 170 fulcrumed at 172 on the framework 160 may be pivotally connected at 174 with the upper portion 168 of the valve member. Oscillation of the lever 170 in a vertical plane about its horizontal fulcrum pivot axis 172 will impart small up-and-down movement to the valve member. Such motion may be effected by a fluid motor 176 fixed on the framework having an upper connection 178 through which hydraulic medium may be pulsed to lift the valve member 164, and a lower connection 180 through which hydraulic medium may be introduced to bias the valve member 164 downwardly in the container 156.

Connecting the lever 170 with the piston rod 182 of the fluid motor 176 is a compensating mechanism 184 to automatically adjust the valve actuating linkage to accommodate thermal expansion or contraction of the elongated valve r-od member 164. One form of such a compensator may comprise a housing 186 including external pivot connections 188 with the lever means 170, and a central piston rod receiving aperture 190 extending therethrough in a direction normal to the axis of the pivot connection 188. A flexible sleeve 192 may be located within the aperture 190, and may be formed by longitudinal slots 194 in a metal sleeve having a relaxed, normal internal diameter only slightly larger than the diameter of the piston rod 182 of the fluid motor 176. A plunger 196 in a laterally extending section of the housing 186 of the compensator may radially abut the split end of the sleeve 192. Hydraulic fluid pulsed through a connection 198 in an end of the housing section serves to bias the plunger 196 laterally against the resilient sleeve 192 and thus clamp the piston rod 182 in a fixed relation to the lever pivot 188. When the valve actuating mechanism is not being operated, and the fluid motor 176 is in its rest position, fluid pressure may be relieved from behind the plunger 196 whereby the inherent resiliency of the split sleeve 192 will restore its normal internal diameter, thus allowing a telescopically sliding compensating adjustment of the connection between the lever pivot 188 and the piston rod 182.

A valve seating spring 200, the tension of which may be adjusted by a nut 202 on the threaded terminus of the piston rod 182, may be employed to bias the housing 186 upwardly to thus impart a desired downward seating pressure :on the valve member 164 in the container 156 when the valve is not being actuated by the fluid motor 176.

The lower rounded end 166 of the valve rod member 164 may extend downwardly into the molten metal in the container 156 and matingly engage an upwardly facing dished valve seat 204 formed in an annular support 206 also of refractory material. The support 206 may include an outer shoulder 208 separating larger and smaller outer diameter portions thereof. The smaller outer diameter portion may be snugly received in an aperture 210 in the bottom wall of the container 156 and its supporting structure, and the larger outer diameter portion may extend upwardly therefrom to position the valve seat 204 away from the container wall whereby molten metal will essentially surround the valving mechanism.

Internally, the support 206 may include a generally downwardly directed delivery port 212 having a narrow upper portion 214 communicating with the valve seat 204, and a wider lower portion 216 opening below the supporting structure 160 for the casting furnace 152. The upper and lower portions of the delivery opening may be connected by a reverse angle shoulder forming a depending or overhanging internal lip 218. Such a lip may be located in the upper portion of the support 206, within the range of the heating coil 154 and the high temperature molten metal which essentially surrounds the valving mechanism. This insures that no metal will freeze in the delivery opening and disrupt operation of the valving mechanism. The entire support 206 including the delivery opening and valve seat may be formed as a replaceable insert whereby a new unit may be substituted for a worn one with very little effort. Furthermore, since the size of the delivery opening 214 governs the rate of flow from the container 156-viscosity and static head remaining constant-the amount of metal metered in a given time may be varied simply by replacing valve seat inserts 206 to utilize the desired orifice size for the particular product being cast.

Between the pouring stations 20 and 24, the station 22 may include a brake to stop rotation of each individual mold holder. Such a device may include a brake shoe 220 secured to the end of the shiftable piston rod 222 of a fluid motor 224. When the shoe 220 is shifted by the motor 224 slowly toward the circular path of the mold holders 12, rotary motion of each holder will be stopped.

The mold holders 12, a plurality of which are positioned around the table 10, are identical in structure, and again a description of one will provide a disclosure of all. Regarding FIGURE 9, each holder 12 may be constructed as a quickly replaceable cartridge unit having an outer flanged insert section 226 insertable in a shouldered aperture 228 in the table 10. The section 226 provides a support for the outer races of a pair of bearings 239, the inner races of which support a hollow spindle 232. A nut 234 threaded on the lower end of the spindle 232 secures the hearings in thrusting relation against an upper shoulder 236. The bearings are shielded from above by a brass cover 238, and the hollow center 240 of the spindle is adapted to allow metal metered from a pouring station to fall on through without injuring the table 10 and holder 12 if by accident there is no mold positioned on the holder. The upper portion of the spindle center 240 is tapered outwardly at 242 to drivingly receive a mold.

Below the table 10, each spindle 232 may include a centrally apertured flywheel 244 removably secured theron by a second nut 246 threaded on the lower end of the spindle. Rotary motion may be imparted to the spindled mold holder by engaging the spinning fiber Wheel 144 directly with the flywheel 244, as can be understood, and such rotary motion will be maintained by the appropriately massive flywheel.

For the purpose of giving coordinated motivation to the various fluid motors described above, there is provided a mechanico-hydraulic programming system for producing a cycle of coordinated movement, illustrated diagrammatically in FIGURES 10a and 10b. This system may be constructed as a self-contained unit having its own housing, not illustrated, which may be positioned at any convenient location on or adjacent the casting machine and connected to the various hydraulic cylinders by a suitable flexible piping. The mechanico-hydraulic drive unit comprises a master camshaft 250 carrying a plurality of cams 252, the followers of which operate the transmitter pistons 254, each of which forms a part of a liquid column type motion transfer device of which there are seventeen units shown in the diagram of FIGURE 10b. Each piston reciprocates in a cylinder 256 having a head B which contains a suitable inlet replenishing check valve 258 and a high pressure relief valve 260 both of which communicate with a low pressure oil reservoir 2.62 preferably formed in a housing enclosing the drive unit.

For turning the camshaft 250, a motor 264 drives an input shaft 266 of a two-speed transmission through a belt drive 268. The input shaft 266 drives a pinion 270 and also the input member of a hydraulically-engaged, spring-released clutch 272. Pinion 270 drives a gear 274 secured to a countershaft 276 which carries a pinion 278 at its opposite end. Pinion 278 drives a gear 280 and therewith constitutes a set of change speed gears. Gear 280 drives the input member of a second hydraulicallyengaged, spring-released clutch 282. The driven members of

clutches

272 and 282 are secured to the opposite ends of a shaft 284, having a worm 286 thereon and brake drum 288. The latter has a spring-biased hydraulic motor 290 for engaging the brake. Worm 286 drives a worm wheel 292 secured to the master camshaft 250.

For the purpose of automatically controlling the starting, stopping, and speed of the transmission, there is provided a hydraulic control pump 294 driven from gear 280, which may circulate a body of oil contained in the housing surrounding the transmission. The pump 294 may deliver to a combined accumulator and relief valve comprising a spring loaded piston 296 and also supplies oil to a bank of

control valves

298, 300 and 302. In the diagrams, each valve is shown as a two-position valve, spring-biased to the position illustrated in which the connections shown in the cross-hatched rectangles are established. Single-headed arrows are used to indicate flow at reservoir pressure and double-headed arrows to indicate flow at a pump delivery pressure. Each of the valves, when shifted, establishes the connections shown in the unhatched rectangles immediately below the hatched rectangles.

Valve 298 is arranged to be shifted by a solenoid 304.

Valves

300 and 302 are arranged to be shifted by the

adjustable cams

306 and 308, respectively, which are positioned on camshaft 250. In addition, the valve 300 has a hydraulic holding cylinder 310 which holds the valve 300 in its shifted position until it is released by the shifting of valve 302. Valve 298 in the position shown delivers pressure fluid to engage the brake 290 and also exhausts fluid to release the low speed cl-utch 282. When shifted, valve 298 exhausts fluid to release brake 290 and supplies pressure fluid to engage the low speed clutch 282, subject, however, to a conjoint control by the valve 300.

The latter valve, in the position illustrated, exhausts fluid to release the high speed clutch 272 and places the low speed clutch 282 under the control of valve 298. In its shifted position, valve 300, provided valve 298 has been shifted, delivers pressure fluid to engage high speed clutch 272 and exhausts fluid to release low speed clutch 282. As previously explained, the valve 302 is merely a reset valve for by-passing the holding cylinder 310 to permit valve 300 to return to its spring biased position shown in the drawings.

Thus, energization of solenoid 304 will start the camshaft rotating at slow speed. Thereafter, the cam 306 will shift the transmission to drive the camshaft at high speed, and still later the cam 308 will against shift the transmission to slow speed. So long as the solenoid 304 remains energized, the camshaft 250 will continue to rotate, first at a slow speed and then at a high speed during each revolution, controlling its own speed changes by operation of the

cams

306 and 308.

For the purpose of controlling the drive motor 263 and solenoid 304, there is provided an electric control circuit connected between a pair of electric supply lines, designated L1 and L2. The circuit may include a master relay 312 of the holding type having a manual master start switch 314 and a manual master stop switch 316. Relay 312 controls the motor 264 and also a cycle control relay 318 of the holding type having a manual cycle start switch 320 and a manual cycle stop switch 322. The normally open contacts of relay 318, which are of the makebefore-break type, control energization of cycle solenoid 304 directly. The normally closed contacts of relay 318 also control solenoid 304, but are in series with a cam switch 324 on the end of, the camshaft 250 and arranged to be opened once during each revolution thereof. The arrangement is such that when the cycle stop switch 322 is operated at any point in the rotation of camshaft 250, relay 318 will be de-energized, but solenoid 304 will remain energized until cam switch 324 opens at the predetermined stopping point. Operation of the master stop switch 316, however, will de-energize solenoid 304 immediately, regardless of the point also de-energize motor 264.

The camshaft 250 as previously mentioned drives a number of cam operated hydraulic pulsator sections designated a through g, inclusive. Each section may comprise units duplicating the single acting pulsating cylinder 256, the head B of which contains the replenishing check valve 258 and the spring closed relief valve 260. All the re plenishing and relief valves are connected to a common oil reservoir 262 formed in the housing of the unit. The reservoir 262 is preferably subjected to a low, super-atmospheric pressure by a body of compressed air or other pressure maintaining arrangements. Check valves 258 allow flow from the reservoir 262 to the cylinder 256, while relief valves 260 allow flow oppositely when the cylinder pressure exceeds a certain value. Thus each of the pairs of

valves

258 and 260 may be referred to as a balancing valve and serve to balance the volume of fluid in each of the liquid column section.

In order to insure proper synchronization of the driving and driven elements of each pulsator section, it is desirable to provide slightly more fluid displacement in the driving or transmitting elements 252256 than is present in their respective fluid motors at the opposite end of the liquid column line. Thus at the end of each advancing stroke of the transmitter piston 254, a small amount of fluid will be discharged to reservoir 262 through its relief valve 260. This amount plus any amount lost by leakage will be returned to the liquid column at the end of the return stroke by the operation of the replenishing valve 258.

In FIGURE 10!; there are shown several circles marked R0 connected to the end of some of the motive cylinders opposite the liquid column connections. These symbols designate the return oil connections by means of which a pulsator system may be hydraulically biased so as to maintain the follower in close contact with the cam as the falling portion of the cam contour recedes from the follower. This bias is maintained by a high pressure accumulator or oil reservoir, not shown, which may be provided with a manifold whereby all of the RO connections are joined together and to the high pressure reservoir. The showing of separate return oil connections in FIGURE 10b is indicative of any suitable type of biasing pressure source, whether it be a single accumulator or multiplicity thereof. The contours of the individual cams 252 are likewise not illustrated in specific detail since they may be formed in accordance with the usual practice to cause motivation of each of the respective hydraulic motors in accordance with the particular operating cycle desired for the machine. Likewise the speed ratio between the high and low speeds of the camshaft 250, and the duration of the high speed portion of the cycle, may be selected as desired through use of the appropriate change gears 270280 and through the adjustment of the

cams

306 and 308, if desired. Of course, the two speed feature of the transmission may be omitted and the high speed clutch 272, the

cams

306 and 308 and the

valves

300 and 302 eliminated.

As can be seen from FIGURE 10b, pulsator section a is connected by its closed liquid column line 326a with the connection 88 of the table locating motor cylinder 84. Pulsator section b is connected by its liquid column 32Gb with the jaw operating fluid motor means for the unloading arm 92. Pulsator section 0 is connected by its liquid column 3260 with the connection 112 of the motor cylinder 106 for swinging the loading arm 90. Pulsator section d is connected by its liquid column 326d with the arm elevating fluid motor for the unloading arm 92. Pulsator section e is connected by its liquid column 326a with the connection 124 of the motor cylinder for elevating the loading arm 90. Pulsator section 1 is connected by its liquid column 326 with the arm swinging fluid motor for the unloading arm 92. Pulsator section g is connected by its liquid column 326g with the in the cycle and will connection 134 of the jaw operating fluid motor means 130 for the loading arm 90. Pulsator section h is connected by its liquid column 326k with the fluid motor 150 for swinging the spin imparting motor against each mold holder flywheel. Pulsator section i is connected by its liquid column 326i with the connection 178 of the metal metering motor 176. Pulsator section j is connected by its liquid column 326 with the fluid motor 224 for shifting the brake 220 against each mold holder flywheel. Pulsator section k is connected by its liquid column 326k with the connection 188 of the first metering valve com pensator. Pulsator section I is connected by its liquid column 3261 with the connection 76 for raising the drive pinion 46 into engagement with the table gear teeth. Pulsator section In is connected by its liquid column 326m with the connection 178 of the metal metering motor 176'. Pulsator section n is connected by its liquid column 326; with the connection 64 of the fluid motor cylinder 58 for oscillating the drive pinion 46 to drive the table. Pulsator section is connected by its liquid column 3260 with the connection 188' of the second metering valve compensator. Pulsator section p is connected by its liquid column 326p with the connection 188" of the third metering valve compensator. And, pulsator section q is connected by its liquid column 326: with the connection 178" of the metal metering motor 176".

It will be noted from FIGURE b that liquid column lines 3261', 326m and 326: are interrupted by three-wlay, two position solenoid actuated

valves

328, 330 and 332, respectively, spring biased to their normal positions in which the connections shown in the cross hatched rectangles are established. These are liquid column disabling valves which, in the normal position shown, allow free operation of the liquid columns but, in the shifted position established the connections shown in the unhatched rectangles whereby the liquid columns are directly connected, or dumped, into the low pressure reservoir 262 thus allowing the

fluid motors

176, 176 and 176" to return to their normal posit-ions responsive to the return bias from the source RO. This closes the metal metering valves at the pouring stations even though the cams at pulsator sections 1', m land q still present rise contours to their respective followers.

The

valves

328, 330 and 332 are each moved to their shifted position by timing

mechanisms

334, 336 and 338, respectively, individually adjustable to determine the length of time the metal metering valves are opened, and thus governing the amount of metal metered to the molds at each of the pouring stations. Each timer is started during every cycle of the machine by suitable electric c'ircuitry of conventional design responsive to a rotary cam activated limit switch 340. As each timer times out and actuates the solenoid after the metal metering valve has been opened by the cam at pulsator sections 1', m or q, the liquid column is disabled and the valve is closed at the adjustable, predetermined time dictated by the timer. Later in the cycle, after the pulsator cams at these stations have again presented their base circles to their fol lowers, a second cam operated limit switch 342 may be employed to reset the two timers and deactivate the solenoids. If desired, of course, the fine adjustment pro vided by the timers may be eliminated, and the metal metering valves may be controlled directly by the cams at the respective pulsator sections.

The mold for articles cast on the above described machine may be of the shell mold variety. A shell mold 344 for an internal combustion engine valve, for instance, may comprise an upper portion 346 and a lower portion 348 bonded together to form an internal cavity 350 defining the shape of the valve to be cast. On the bottom of the lower section of the mold, a tapered boss 352 may form a driving fit with the mating taper 242 of the spindled mold holder 12. The upper part of the mold rn'ay flare out to form a feed pocket 354 for excess metal to feed the shrink as the casting cools. It will be clear that any suitable mold may be employed according to the article being cast, and the spindled holders 12 adapted thereto.

In operation, with molten metal of the desired varieties in each of the

containers

152, 152' and 152" at the pouring

stations

18, 20 and 24, and with suitable molds in the holders 12, the composite centrifugal casting machine undergoes repeated cycles of coordinated motion responsive to the mechanico-hydraulic motivator.

Fresh shell molds are cast, assembled and then continually fed by the belt conveyor 136 to the loading station 14, where they are loaded one at a time on the table 10 by the loading arm 90. During one portion of the machine cycle, this arm first grips the mold with the jaws 126 under control of motivator section g, then raises bodily under control of motivator section e, and then swings horizontally under control of motivator section 0. After the mold is thus presented above a newly presented empty holder 12, the arm lowers and the jaws thereafter open to deposit the mold on the table. The arm will next swing back to the supply station to get another mold.

Simultaneously, the unloading arm 92 goes through its above-noted cycle under control of motivator sections b, d and f to grip a filled mold, raise it out of the holder 12, swing it above the shaker screen conveyor 140, and release it.

Also, while the table 10 is stopped, the locating and locking finger 78 under control of motivator section a holds the table in its newly indexed position while the rack 54 for the index drive pinion 46 is being reset.

Furthermore, during this time, the fluid motor 150, controlled by motivator section it nudges the secondary fiber drive wheel 144 against a flywheel 244 presented at station 16 to impart spin to an empty mold; and, the fluid mot-or 224 controlled by motivator section j urges the brake 220 against a flywheel 244 presented at station 22 to remove spin from a partially filled mold.

Finally, during table stop time, the three

valves

164, 164' and 164" at

stations

18, 20 and 24 are ope-rated by motivator sections i, m and q, respectively, to meter predetermined amounts of different molten metals to molds positioned at the respective pouring stations.

To meter metal, the valve rod 164 in the casting furnace is raised slightly from its dished seat 204 by the fluid motor 176 controlled from motivator section i of the m-echanico-hydraulic motivator. While the valve rod 164 is oil its seat, metal pressurized by the static head of molten metal in the pot 156 flows across the seat 204 and out the outlet opening 214 of the valve mechanism and then flows by gravity directly into the mold 344. With a given viscosity to the molten metal, a given size to the orifice 214, and a static head of metal within allowable tolerances, the quantity of metal metered from the casting furnace to the mold may be very accurately controlled by the amount of time the valve 164 is held off its seat by the mechanico hydraulic motivator. The valve may be closed by operation of the timer controlled solenoid valve 328 for disabling the liquid column 326i which actuates the fluid motor 176.

During the other portion of the machine cycle, the table 10 may be indexed to shift each mold one step farther along the path beneath the trio of pouring stations. The drive pinion 46 is raised by the fluid motor cylinder 72 under control of motivator section I to engage with the teeth 38 of the table; thereafter, the pinion 46 is rotated by the motor cylinder 58 responsive to motivator section n.

During this latter portion of the machine cycle, of course, the loading and unloading arms are not working over the table, and the fiber drive wheel 144 and the brake 220 are idled, as are the three metal metering valves Eat the pouring stations. Continued rotation of the camshaft 250 thus powers and controls repeated cycles of coordinated motion of the various parts of the composite centrifugal casting machine of this invention.

The casting method of this invention carried out by the above described machine is best understood by following the travel of a given mold 344 after it is loaded 'on the table at station 14 and until it is unloaded therefrom at tation 26. First, at station 16, the mold is spun about its vertical axis.

Then, regarding FIGURE 11, a small predetermined quantity of molten metal 356 is metered to the mold at station v18. It falls by gravity to the bottom and is thence displaced by centrifugal force to the peripheral zone of the mold defining the conical seat of the engine valve. This forms a ring of molten metal.

As the metal ring cools, its centrifugally inner, or exposed surface first forms a frozen skin which gradually thickens toward the center of the quantity. This forms a flow barrier which, when molten metal is subsequently poured onto it, prevents flow of the second molten metal into the first molten metal on the other side of the barrier.

Regarding FIGURE 12, another small predetermined quantity of a different molten metal 358 is also metered to the mold at staiton 20. By [this time the first quantity of metal 356 is not yet frozen solid, and the second quantity 358 flows by gravity and centrifugal force against the barrier and remains in contact therewith; it fills the mold part way up the zone defining the concentric operating stem of the engine valve.

Where the two metals meet, the barrier is remelted and the two metals blend and intermingle in the space occupied by the barrier. If the first-poured metal, for instance, has a comparatively high melting point, the second metal will be cast at a temperature high enough to remelt the skin on the first metal before the temperature of the second metal falls below such a point. Depending upon the temperatures, melting points, alloy compositions, specific gravities, the amount of centrifugal force and the like, the zone of fusion 360 may be fully controlled. It Will be an annular zone of'a radial thickness deep enough for a thorough bond between the two metals yet limited so that none of the second poured metal 358 reaches the outer edge of the casting in the area that will be the seat of the finished cast valve.

As the blended joint cools, the upper surface of the second poured metal 302 also forms a second surface skin or barrier thereon. Burning of the mold sand bonding medium continually generates an atmosphere in the mold which inhibits oxide formations on the first two shots of metal as they cool. While the inner body of the second metal behind the barrier is still above the freezing point, however, a third amount of molten metal 362 is metered to the mold at station 24, see FIGURE 13, after the axial spin has been subtracted from the mold by the brake 220 at station 22.

This third :amount of metal fills the mold up to the feed cup 354. It remelts the barrier on the upper surface of the second amount 358 and blends therewith through a juncture zone 364. This latter zone, depending upon the temperatures, melting points, alloy compositions, and the like may be controlled to provide a strong union with its depth limited, however, to a predetermined range.

Cooling of the entire casting results in a tri-rnetal valve, after the mold and the upper feed sprue are removed, having different metals in the portions which encounter different conditions in the valves operational environment. Regarding FIGURE 14, the flared head portion 366 of the cast valve 368 is composed entirely of the second poured metal 358. The surrounding conical seat portion 370 is composed entirely of the first poured metal 356.

Thezone 360 where these two metals blend together is superior to a weld joint, aside from the obvious cost savings, in that among other things the characteristics of one metal merge or graduate into the characteristics of the other over a significant radial extent. There is no abrupt line of demarcation therebetween as in a Weld joint to interrupt thermal conduction or heat flow from the valve head to the seat, and diverse coefficients of thermal ex- 12 plansion do not occur'in immediate side by side relations 1p.

The concentric operating stem portion 372 is composed entirely of the third poured amount of metal 362. The bond or junction at 364 joining the stem portion metal with the head portion metal again'has the above noted advantages over a common weld joint. 1

Depending upon the metals chosen for the various parts of the valve, heat treatment may be desirable to develop the metallurgical qualities desired. This may involve no more than induction hardening the tip 374 of the valve stem 372. Typical examples of metals which may be employed to advantage in exhaust valves for internal combustion engines are as follows.

The first-poured metal 356 to form the conical seat portion of the valve may be a cobalt-nickel base metallic alloy. As used herein, a cobalt-nickel base alloy is one in which the sum of the cobalt and the nickel percentages by weight is above fifty percent; for instance, the two may total above fifty percent, or one or the other alone may exceed fifty percent to be balanced by smaller amounts of the other, or even to the total exclusion of the other. Such an alloy has excellent resistance to corrosion from the combustion products of leaded fuels, especially at high temperatures. Furthermore, it is highly resistantto scuffing and wear. Examples of such having these characteristics are:

1 Maximum.

For the second-poured metal 358 to form the flanged head portion of the valve, an austenitic steel is preferred. Such a ferrous base alloy has sufficient alloying elements such as manganese, chromium and nickel to form an austenitic structure. Such a steel is not prohibitively expensive and has resistance to corrosion in the manner of the stainless steels. Furthermore, it has mechanical properties such as strength and toughness even in the higher temperature ranges encountered in modern heavy duty internal combustion engines. And, like the cobalt-nickel base alloy, it will not be adversely affected by any heat treatment to which the valve stem may subsequently be subjected. Examples of such having these characteristics are:

C 1.00 .20 1.00 .25 .50 Mn 7.00 1. 25 1 75 Cr 21. 0O 21. 00 15. 50 26. 00 15. 00 Ni... 2. 25 12. 00 14. 00 5. 00 15. 00 S il 1. 00 l 1. 50

1 Maximum. 2 Balance.

Finally, for the third-poured metal 362 to form the operating stern portion of the valve, a steel having sufiicient carbon plus carbide stabilizers so that it will form martensite and can be even further hardened by heat treatment is preferred. In this class fall the tool steels which, even before appropriate hardening, are extremely resistant to mechanical wear from rubbing and sending. While not as corrosion resistant as the cobalt-nickel base alloys nor as tough at high temperatures as the austenitic steel alloys, it has wear qualities to Withstand the continual rubbing by the cam, rocker arm or other valve actuator. With such steels, after an annular groove is machined on 13 the stem of the cast valve, for a spring retainer, further hardening of the stem tip may be attained by induction hardening or other known heating and quenching steps. Examples of such hardenable steel alloys having these characteristics are:

1 Minimum. 2 Balance.

These metals are given as examples only, and it will be clear that many others in each class may be employed within the scope of the defined invention depending upon the desired finished product.

FIGURE illustrates a finished valve 368 in its operational environment. A spring retainer 376 is aflixed to the annularly grooved valve stem. A heavy valve seating spring 378 acts between the retainer and the internal combustion engine 380 to bias the valve head 366 upwardly so that the conical seat 370 closes against a mating insert 382 fixed in the engine. The valve stem 372 is reciprocable in a tubular valve guide 384 also fixed in the engine. Downward motion of a valve actuator 386, such as a cam or rocker arm, compresses the valve spring 378 and moves the valve head downwardly away from the seat insert 382 into the combustion chamber to open the valve, as is well known, and subsequent upward motion of the actuator 386 allows the spring 378 to again seat the valve.

Thus a casting machine and method for producing an improved engine valve have been disclosed. The machine may be used for any number of divergent products requiring a first metal on an outside wall and a second metal on the inside, for it will be obvious that one or more of the pouring stations may be rendered inoperative for casting articles of less than three metals; on the other hand, more pouring stations may be provided with mold spinning and braking stations placed as desired for centrifugally casting articles of more than three metals, all within the scope of the invention.

The method of casting, while entirely suitable for producing internal combustion engine exhaust valves, also lends itself to casting divergent products. Engine valves may be continually cast at the rate of one per cycle of the machine-every several seconds. The method is very inexpensive when considered against the improved product result, and it is made possible by the controlled metering of small predetermined amounts of high melting temperature metal from a bottom pour furnace. Furthermore, the mechanico-hydraulic motivator aids in controlling the critical time lapse between successive pours of different molten metals to a given mold.

Finally, the improved metallurgical characteristics of the disclosed valve product or article meet a current need in the internal combustion engine industry.

While the above described embodiment constitutes a preferred mode of carrying out this invention, many other forms might be adopted within the scope of the actual invention, which is variously claimed as:

I claim:

1. A method of casting a small composite article comprising providing a mold having a cavity defining the shape of the article, maintaining plural sources of different molten metals at elevated temperatures, placing the mold at one of the sources of molten metal, metering a predetermined amount of one molten metal therefrom to flow by gravity into the mold cavity, applying a secondary force to overcome gravitational force and displace the molten metal to a desired zone in the mold cavity, cooling the displaced amount of molten metal to freeze only a surface skin thereon while placing the mold at another of the sources of molten metal, metering a predetermined amount of another molten metal therefrom to flow into the mold cavity into contact with the displaced amount of molten metal, remelting surface skin on the displaced amount of metal where it contacts the newly metered amount of metal, gradually cooling both amounts of metal together in the mold cavity and removing the secondary force to provide an autogenously united article having metallurgical characteristics of the one metal in one portion and metallurgical characteristics of the other metal in another portion.

2. A method of casting a valve of the type having a flanged head portion including a peripheral conical seat portion and a generally concentric operating stem portion comprising placing a ring-shaped quantity of cobalt-nickel base metallic alloy to form the peripheral seat portion into contact with a flange-shaped quantity of austenitic steel alloy to form the remainder of the head portion, one of the quantities of alloy being entirely molten and the other being solid only on its outer surface and otherwise molten when placed in contact, melting the solid outer surface where the two quantities are in contact so that the two quantities Will blend in the molten state throughout an annular fusion zone of substantial radial extent, and then freezing both quantities of alloy to form an autogenously united casting having a cobalt-nickel base metallic alloy seat portion around a head portion of austenitic steel alloy.

3. A method of casting a valve of the type having a flanged head portion including a peripheral conical seat portion and a generally concentric operating stem portion comprising placing a flange-shaped quantity of austenitic steel alloy to form the head portion into contact With a rod-shaped quantity of hardenable steel alloy to form the stem portion, one of the quantities of steel alloy being entirely molten and the other being solid only on its outer surface and otherwise molten when placed in contact, melting the solid surface where the two quantities are in contact so that the two quantities will blend in the molten state throughout a limited fusion zone, and then freezing both quantities of steel alloy to form an autogenously united casting having an austenitic steel alloy head portion joined to a stern portion of hardenable steel alloy.

4. A method of casting a valve of the type having a flanged head portion including a peripheral conical seat portion and a generally concentric operating stem portion comprising placing a ring-shaped quantity of cobalt-nickel base metallic alloy to form the peripheral seat portion into contact with a flange-shaped quantity of austenitic steel alloy to form the remainder of the head portion, the quantity of austenitic steel alloy being entirely molten and the ring-shaped quantity of cobalt-nickel base alloy being solid only on its outer surface and otherwise molten when placed in contact, blending the two quantities in the molten state throughout a limited fusion zone where they contact, freezing the joined quantities of alloy until the flange-shaped quantity is solid in the portion remote from the cobalt-nickel base alloy on only its outer surface, then placing a rod-shaped quantity of hardenable steel alloy to form the stem portion into contact with the solid outer surface of the flange-shaped quantity, the rod-shaped quantity being entirely molten, and finally blending the austenitic steel alloy with the hardenable steel alloy throughout a limited fusion zone where they contact to form thereby an autogenously united casting of a valve having a cobaltnickel base metallic alloy seat portion around a head portion of austenitic steel alloy joined to a stern portion of hardenable steel alloy.

5. A method of casting a valve of the type having a flanged head portion including a peripheral conical seat portion and a generally coaxial operating stem portion comprising providing a shell mold having a cavity defining the shape of the valve, positioning the mold with the 15 cavity axis generally vertical, allowing to fiow by gravity into the mold cavity a predetermined quantity of molten cobalt-nickel base metallic alloy, rotating the mold about its cavity axis to displace the molten alloy radially outwardly by centrifugal force to the zone of the cavity defining the seat portion of the valve, forming a non-liquid barrier on the exposed surface of the molten cobalt-nickel alloy then allowing to flow by gravity into the mold cavity a quantity of molten austenitic steel alloy to fill at least the zone of the cavity defining the head portion of the valve, the latter alloy being hotter than the melting point of the former alloy whereby the barrier will be melted and the two alloys will blend throughout a substantial juncture zone to provide an autogenously united casting having a cobalt-nickel base metallic alloy seat portion around a head portion of austenitic steel alloy.

6. A method of casting a valve of the type having a flanged head portion including a peripheral conical seat portion and a generally coaxial operating stem portion comprising providing a shell mold having a cavity defining the shape of the valve, positioning the mold with the cavity axis generally vertical, allowing to flow by gravity into the mold cavity a predetermined quantity of molten cobalt-nickel base metallic alloy, rotating the mold about its cavity axis to displace the molten alloy radially outwardly by centrifugal force to fill only the zone of the cavity defining the seat portion of the valve, continuing to rotate the mold at least until a surface skin has begun to freeze on the displaced alloy, then allowing to flow by gravity into the mold cavity a quantity of molten austenitic steel alloy to fill the zone of the cavity defining the head portion of the valve, joining these two alloys where they contact each other by remelting surface skin of the cobalt-nickel base alloy, freezing surface skin on the austenitic steel alloy in the zone of the mold cavity where the valve head portion merges with the stem portion, filling the mold cavity with molten hardenable steel alloy, joining the two steel alloys where they contact each other by remelting surface skin of the austenitic steel alloy, and freezing all the alloy in the shell mold to provide an autogenously united casting of a valve having a cobaltnickel base metallic alloy seat portion around a head portion of austenitic steel alloy joined to a stem portion of hardenable steel alloy.

7. A method of casting a valve of the type having a flanged head portion including a peripheral conical seat portion and a generally coaxial operating stem portion comprising providing a shell mold having a cavity defining the shape of the valve, positioning the mold with the cavity axis generally vertical, allowing to flow by gravity into the mold cavity a predetermined quantity of molten cobalt-nickel base metallic alloy, rotating the mold about its cavity axis to displace the molten alloy radially outwardly by centrifugal force to fill only the zone of the cavity defining the seat portion of the valve, continuing to rotate the mold at least until a surface skin has begun to freeze on the displaced alloy, then allowing to fiow by gravity into the mold cavity a quantity of molten austenitic steel alloy to fill the zone of the cavity defining the head portion of the valve, joining these two alloys where they contact each other by remelting surface skin of the cobalt-nickel base alloy, freezing surface skin on the austenitic steel alloy in the zone of the mold cavity where the valve head portion merges with the stem portion, filling the mold cavity with molten hardenable steel alloy, joining the two steel alloys where they contact each other by remelting surface skin of the austenitic steel alloy, freezing all the alloy in the shell mold, removing the frozen alloy from the mold and then heat treating a portion of the hardenable steel alloy to provide an autogenously united casting of a valve having a cobalt-nickel base metallic alloy seat portion around a head portion of austenitic steel alloy joined to a stem portion of another steel alloy a portin of which is significantly harder than in the as-cast state.

8. A method of continuously casting valves of the type having a flanged head portion including a peripheral conical seat portion and a generally coaxial operating'stem portion comprising shifting in one direction along a path molds each having a cavity defining the shape of the valve, maintaining a supply of molten cobalt-nickel base metallic alloy at a first point along the path and a supply of molten austenitic steel alloy at a second point farther along the path, simultaneously metering at preset time intervals a predetermined quantity of molten alloy from each supply into two molds positioned respectively at the first and second points along the path, and axially spinning each mold as it shifts along the path to displace the predetermined quantity of molten cobalt-nickel base alloy therein by centrifugal force to the zone of the mold cavity defining the peripheral conical seat portion prior to the metering of the predetermined quantity of austenitic steel alloy thereinto at the second point farther along the path.

9. A method of continuously casting valves of the type having a flanged head portion including a peripheral conical seat portion and a generally coaxial operating stem portion comprising shifting in one direction along a path molds each having a vertically disposed cavity defining the shape of the valve with the stem portion upwards, maintaining a supply of molten cobalt-nickel base metallic alloy at a first point along the path and a supply of molten austenitic steel alloy at a second point farther along the path and a supply of molten hardenable steel alloy at a third point even farther along the path, simultaneously metering at preset time intervals at predetermined quantity of molten alloy from each supply into three molds positioned respectively at the first, second and third points along the pat-h, adding axial spin to each mold as it shifts along the path to displace the predetermined quantity of molten cobalt-nickel base alloy therein by centrifugal force to the zone of the mold cavity defining the peripheral conical seat portion prior to the metering of the predetermined quantity of austenitic steel alloy thereinto at the second point along the path, and subtracting axial spin from each mold prior to the metering of the predetermined quantity of harden'able steel alloy thereinto at the third point along the path.

10. The method of casting a generally T-shaped engine valve having a peripheral conical seat portion on a head flange on a rod-shaped stem, which method includes pouring into a valve mold a quantity of molten cobaltnickel base alloy sufficient to form the seat portion, rotating the mold to displace the cobalt-nickel alloy against the force of gravity into the rim of the mold to form the seat portion, forming from the cobalt-nickel alloy on the exposed surface thereof a flow barrier sufficient to prevent the flow of molten metal through the barrier while maintaining the alloy molten adjacent the barrier, pouring onto the barrier a quantity of austenitic steel alloy sufiicient to occupy only a part of the remainder of the mold and to form at least the remainder of the head of the valve, maintaining for a time the austenitic steel and the cobalt-nickel allow both molten in contact with the barrier throughout the surface of the barrier, melting the barrier and mixing the molten cobalt-nickel and the molten austenitic steel alloys in the space which had been occupied by the barrier, forming from the austenitic steel on the exposed surface thereof a second flow barrier sufiicient to prevent flow of molten metal through the barrier while maintaining the austenitic steel molten adjacent the second barrier, pouring onto the second barrier a quantity of molten harden-able steel alloy sufficient to fill the remainder of the mold and form at least part of the stem of the valve, keeping molten for a time both the austenitic steel and the hardenable steel adjacent the second barrier, melting the second barrier and mixing the molten austenitic steel and molten har-cl'enable steel in the space occupied by the barrier, and cooling all three metals to form a valve having a cobalt-nickel alloy seat portion autogenously united to an austenitic steel head 17 in a juncture zone of substantial radial extent formed in the space which had been occupied by the first barrier by a progressive blend of metal ranging from cobaltnickel alloy to austenitic steel alloy and having a hardenable steel stem autogenously united'to the head in a juncture zone of substantial axial extent formed in the space which had been occupied by the second barrier by a progressive blend of metal ranging from austenitic steel alloy to hardenable steel alloy.

11. The method of casting "a generally T-shaped engine valve having a peripheral conical seat portion on a head flange on a rod-shaped stem, which method includes pouring into a valve mold a quantity of molten first metal suflicient to form the seat portion, rotating the mold to displace the molten metal against the force of gravity into the rim of the mold to form the seat portion, forming from the first metal on the exposed surface thereof a flow barrier sufficient to prevent the flow of molten metal through the barrier while maintaining the metal molten adjacent the barrier, pouring onto the barrier a quantity of a second metal sufiicient to occupy only a part of the remainder of the mold and to form at least the remainder of the head of the valve, maintaining for a time the second metal and the first metal both molten in contact with the barrier throughout the surface of the barrier, melting the barrier and mixing the molten metals in the space which had been occupied by the barrier, forming from the second metal on the exposed surface thereof a second flow barrier sufiicient to prevent flow of molten metal through the barrier while maintaining the second metal molten adjacent the second barrier, pouring onto the second barrier a quantity of molten third metal sufficient to fill the remainder of the mold and form at least part of the stem of the valve, keeping molten for a time both the second metal and the third metal adjacent the second barrier, melting the second barrier and mixing the molten second and third metals in the space occupied by the barrier, and cooling all three metals to form a valve having a seat portion of one metal autogenously united to a head of another metal in a juncture zone of substantial radial extent formed in the space which had been occupied by the first barrier by a progressive blend of metal ranging from the first metal to the second and having a stem of a third metal autogenously united to the head in a juncture zone of substantial axial extent formed in the space which had been occupied by the second barrier by a progressive blend of metal ranging from the second metal to the third metal.

12. The method of casting a generally T-shaped engine valve having a peripheral conical seat portion on a head flange, which method includes pouring into a valve mold a quantity of molten cobalt-nickel base alloy sufficient to form the seat portion, rotating the mold to displace the cobalt-nickel alloy against the force of gravity into the rim of the mold to form the seat portion, forming from the cobalt-nickel alloy on the exposed surface thereof a flow barrier suflicient to prevent the flow of molten metal through the barrier while maintaining the alloy molten adjacent the barrier, pouring onto the barrier a quantity of austenitic steel alloy suflicient to form at least the remainder of the head of the valve, maintaining for a time the austenitic steel and the cobalt-nickel alloy both molten in contact with the barrier throughout the surface of the barrier, melting the barrier and mixing the molten cobalt-nickel and the molten austenitic steel alloys in the space which had been occupied by the barrier, and cooling both metals to form a valve having a cobaltnickel alloy seat portion autogenously united to an austenitic steel head in a juncture zone of substantial radial extent formed in the space which had been occupied by the barrier by a progressive blend of metal ranging from cobalt-nickel alloy to austenitic steel alloy.

13. The method of casting a generally T-shaped engine valve having a head flange on a rod-shaped stem, which method includes pouring into a valve mold a quantity of austenitic steel alloy sufficient to occupy only a part of the mold and to form at least a part of the head of the valve, forming from the austenitic steel on the exposed surface thereof a flow barrier suflicient to prevent flow of molten metal through the barrier while maintaining the austenitic steel molten adjacent the barrier, pouring onto the barrier a quantity of molten hardenable steel alloy sufiicient to form at least part of the stern of the valve, keeping molten for a time both the austenitic steel and the hardenable steel adjacent the barrier, melting the barrier and mixing the molten austenitic steel and molten hardenable steel in the space occupied by the barrier, and cooling both metals to form a valve having a hardenable steel stem autogenously united to an austenitic steel head in a juncture zone of substantial axial extent formed in the space which had been occupied by the barrier by a progressive blend of metal ranging from austenitic steel alloy to hardenable steel alloy.

14. The method of casting a generally T-shaped engine valve having a peripheral conical seat portion on a head flange, which method includes pouring into a valve mold a quantity of molten first metal sufficient to form the seat portion, rotating the mold to displace the molten metal against the force of gravity into the rim of the mold to form the seat portion, forming from the first metal on the exposed surface thereof a flow barrier suflicient to prevent the flow of molten metal through the barrier while maintaining the metal molten adjacent the barrier, pouring onto the barrier a quantity of a second metal sutficient to form at least the remainder of the head of the valve, maintaining for a time the second metal and the first metal both molten in contact with the barrier throughout the surface of the barrier, melting the barrier and mixing the molten metals in the space which had been occupied by the barrier, and cooling both metals to form a valve having a seat portion of one metal autogenously united to a head of another metal in a juncture zone of substantial radial extent formed in the space which had been occupied 'by the barrier by a progressive blend of metal ranging from the first metal to the second.

15. The method of casting a generally T-shaped engine valve having a head flange on a rod-shaped stem, which method includes pouring into a valve mold a quantity of molten first metal sufiicient to occupy only a part of the mold and to form at least a part of the head of the valve, forming from the first metal on the exposed surface thereof a flow barrier sufficient to prevent flow of molten metal through the barrier while maintaining the metal molten adjacent the barrier, pouring onto the barrier a quantity of molten second metal sufficient to form at least part of the stem of the valve, keeping both metals molten for a time adjacent the barrier, melting the barrier and mixing the molten metals in the space occupied by the barrier, and cooling both metals to form a valve having a stem of one metal autogenously united to a head of another metal in a juncture zone of substantial axial extent formed in the space which had been occupied by the barrier by a progressive blend of metal ranging from one metal to the other.

16. The method of casting a generally T-shaped engine valve having a peripheral conical seat portion on a head flange on a rod-shaped stern, which method includes pouring into a valve mold a quantity of molten cobalt-nickel base alloy sufiicient to form the seat portion, rotating the mold to displace the cobalt-nickel alloy against the force of gravity into the rim of the mold to form the seat portion, pouring onto the cobalt-nickel alloy a quantity of austenitic steel alloy sufiicient to occupy only a part of the remainder of the mold and to form at least the remainder of the head of the valve. mixing the molten cobalt-nickel and the molten austenitic steel alloys while controlling the radial extent of mixing at the interface, pouring 'onto the austenitic steel a quantity of molten hardenable steel alloy suflicient to fill the remainder of the mold and form at least part of the stem of the valve, mixing the molten austenitic steel and molten hardenable steel while controlling the axial extent of mixing at the interface, and cooling all three metals to form a valve having a cobalt-nickel alloy seat portion autogenously united to an austenitic steel head in a juncture zone of substantialbut limited radial extent formed -by a progressive blend of metal ranging from cobalt-nickel alloy to austenitic steel alloy and having a hardenable steel stern autogenously united to the head in a juncture zone of substantial but limited extent by a progressive blend of metal ranging from austenitic steel alloy to hardenable steel alloy.

17. The method of casting a generally T-shaped engine valve having a peripheral conical seat portion on a head flange on a rod-shaped stem, which method includes pouring into a valve mold a quantity of molten first metal sufficient to form the seat portion, rotating the mold to displace the molten metal against the force of gravity into the rim of the mold to form the seat portion, pouring onto the first metal a quantity of a second metal sufficient to occupy only a part of the remainder of the mold and to form at least the remainder of the head of the valve, mixing the molten metals while controlling the radial extent of mixing at the interface, pouring onto the second metal a quantity of molten third metal suflicient to fill the remainder of the mold and form at least part of the stem of the valve, mixing the molten second and third metals while controlling the axial extent of mixing at the interface, and cooling all three metals to form a valve having a seat portion of one metal autogenously united to a head of another metal in a juncture zone of substantial but limited radial extent by a progressive blend of metal ranging from the first metal to the second and having a stern of a third metal autogenously united to the head in a juncture zone of substantial but limited axial extent by a progressive blend of metal ranging from the second metal to the third metal.

18. The method of casting a generally T-shaped engine valve having a peripheral conical seat portion on a head flange, which method includes pouring into a valve mold a quantity of molten cobalt-nickel base alloy sutficient to form the seat portion, rotating the mold to displace the cobalt-nickel alloy against the force of gravity into the rim of the mold to form the seat portion, pouring onto the cobalt-nickel alloy a quantity of austenitic steel alloy sufiicient to form at least the remainder of the head of the valve, mixing the molten cobalt-nickel and the molten austenitic steel alloys while controlling the radial extent of mixing at the interface, and cooling both metals to form a valve having a cobalt-nickel alloy seat portion autogenous- 1y united to an austenitic steel head in a juncture zone of substantial but limited radial extent formed by a progressive blend of metal ranging from cobalt-nickel alloy to austenitic steel alloy.

19. The method of casting a generally T-shaped engine valve having a peripheral conical seat portion on a head flange, which method includes pouring into a valve mold a quantity of molten first metal suflicient to form the seat czi portion, rotating the mold to displace the molten metal against the force of gravity into the rim of the mold to form the seat portion, pouring onto the first metal a quantity of a second metal sufficient to form at least the remainder of the head of the valve,rnixing the molten metals while controlling the radial extent of mixing at the interface, and cooling both metals'to form a valve having a seat portion of one metal autogenously united to a head of another metal in a juncture zone of substantial but limited radial extent formed by a progressive blend of metal ranging from the first metal to the second.

20, The method of casting a generally T-shaped engine valve having a head flange on a rod-shaped-stem, which method includes pouring into a valve mold a quantity of molten austenitic steel alloy suflicient to occupy'only apart of the mold and to form at least part of the head of the valve, pouring onto the austenitic steela quantity of molten hardenable steel alloy sufiicient to fill the remainder of the mold and form at least part of the stem of the valve, mixing the molten austenitic steel and molten hardenable steel While controlling the axial extent of mixing, and coo-ling both metals to form a valve having a hardenable steel stern autogenously united to an austenitic steel headin a juncture zone of substantial but limited axial extent by a progressive blend of metal ranging from austenitic steel alloy to hardenable steel alloy.

21. The method of casting a generally T-shaped engine valve having a head flange on a rod-shaped stem, which method includes pouring into a valve mold a quantity .of molten first metal sufficient to form at least part of the head of the valve, pouring onto the first metal a quantity of molten second metal sufiicient to fill the remainder of the mold and form at least part of the stern of the valve, mixing the molten metals while controlling the axial extent of mixing at the interface, and cooling the metals to form a valve having a stem of one metal autogenously united to the head in a juncture zone of substantial but limited axial extent formed by a progressive blend of metal ranging from one metal to the other metal.

References Cited UNITED STATES PATENTS 2,483,849 10/1949 Seaman 22206 2,837,799 6/1958 Priebe et al. 22206 2,294,803 9/1942 Rich -2 123188 2,881,750 4/1959 Hanink 123188 1,885,465 11/ 1932 Moulton 22585 1,917,872 7/1933 Campbell 2258.5 1,423,876 7/1922 Pfanstiehl 123-188 1,444,210 2/1923 Rich 123-188 1,770,582 7/1930 Greiner et a1 22200.5 1,806,972 5/1931 McCarroll et al.

2,270,822 1/ 1942 Cape.

2,479,039 8/1949 Cronstedt 22205 2,495,731 1/1950 Jennings l23-188 1,770,582 7/1930 Pike 222005 2,710,997 6/1955 Krepps 22200.5

J. SPENCER OVERHOLSER, Primary Examiner.

Claims

1. A METHOD OF CASTING A SMALL COMPOSITE ARTICLE COMPRISING PROVIDING A MOLD HAVING A CAVITY DEFINING THE SHAPE OF THE ARTICLE, MAINTAINING PLURAL SOURCES OF DIFFERENT MOLTEN METALS AT ELEVATED TEMPERATURES, PLACING THE MOLD AT ONE OF THE SOURCES OF MOLTEN METAL, METERING A PREDETERMINED AMOUNT OF ONE MOLTEN METAL THEREFROM TO FLOW BY GRAVITY INTO THE MOLD CAVITY, APLYING A SECONDARY FORCE TO OVERCOME GRAVITATIONAL FORCE AND DISPLACE THE MOLTEN METAL TO A DESIRED ZONE IN THE MOLD CAVITY, COOLING THE DISPLACED AMOUNT OF MOLTEN METAL TO FREEZE ONLY A SURFACE SKIN THEREON WHILE PLACING THE MOLD AT ANOTHER OF THE SOURCES OF MOLTEN METAL, METERING A PREDETERMINED AMOUNT OF ANOTHER MOLTEN METAL THEREFROM TO FLOW INTO THE MOLD CAVITY INTO CONTACT WITH THE DISPLACED AMOUNT OF MOLTEN METAL, REMELTING SURFACE SKIN ON THE DISPLACED AMOUNT OF METAL WHERE IT CONTACTS THE NEWLY METERED AMOUNT OF METAL, GRADUALLY COOLING BOTH AMOUNTS OF METAL TOGETHER IN THE MOLD CAVITY AND REMOVING THE SECONDARY FORCE TO PROVIDE AN AUTOGENEOUSLY UNITED ARTICLE HAVING METALLURGICAL CHARACTERISTICS OF THE ONE METAL IN ONE PORTION AND METALLURGICAL CHARACTERISTICS OF THE OTHER METAL IN ANOTHER PORTION.