US3581802A - Method for making castings - Google Patents

Method for making castings Download PDF

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Publication number
US3581802A
US3581802A US795570*A US3581802DA US3581802A US 3581802 A US3581802 A US 3581802A US 3581802D A US3581802D A US 3581802DA US 3581802 A US3581802 A US 3581802A
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US
United States
Prior art keywords
granular material
gaseous fluid
container
casting
admitting
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
US795570*A
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English (en)
Inventor
Erich Krzyzanowski
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Saint Gobain Isover G+H AG
Original Assignee
Gruenzweig und Hartmann AG
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Publication date
Application filed by Gruenzweig und Hartmann AG filed Critical Gruenzweig und Hartmann AG
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Publication of US3581802A publication Critical patent/US3581802A/en
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/02—Sand moulds or like moulds for shaped castings
    • B22C9/04—Use of lost patterns
    • B22C9/046—Use of patterns which are eliminated by the liquid metal in the mould
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C11/00—Moulding machines characterised by the relative arrangement of the parts of same

Definitions

  • the present invention relates generally to casting of materials, and more particularly to a method of making castings.
  • the invention so relates to an apparatus for carrying out the method.
  • This invention is particularly concerned with the type of casting method wherein a casting mold or casting form is used consisting of a material which will be consumed by contact with the molten metal.
  • Such casting forms may be made of relatively inexpensive material and/or of material which is quite thin and therefore not in itself very resistant, because they are embedded in sand or other granular material and thereby reinforced.
  • the granular material in which the latter is embedded be compacted rather solidly about the form or to provide the granular material with binders of known type so as to prevent breakout of the molten material beyond the outline of the form when the latter is consumed.
  • a more particular object of the invention is to provide a casting method of the general type outlined above which is extremely simple and economical and which eliminates manual operations to a very significant extent.
  • a further object of the invention is to provide such a method which, despite all of its advantages, permits the use of consumable forms despite their low mechanical strength.
  • An additional object of the invention is to provide an apparatus carrying out the novel method.
  • one feature of my invention resides in the provision of a method for making castings according to which I confine a body of granular material in a container and thereupon admit into a bottom region of the container a stream of gaseous fluid requisite for agitating the granular material and for imparting the body a state at least approaching fluidization.
  • Admission of the gaseous fluid is now terminated whereby the granular material settles about and into contact with the form, becoming compacted by such settling and tightly embedding the form.
  • the molten metal is now introduced into the form and fills the same, assuming the configuration of the form while simultaneously consuming the latter.
  • the gaseous fluid is again admitted into the bottom region of the container whereby the granular material is again agitated to facilitate removal of the finished casting from the body of granular material.
  • My novel method permits the embedding of consumable forms of very highly complicated outline in the granular material without having to make allowance for the low mechanical resistance of lightweight, thin and otherwise readily damaged molds and cast articles. Furthermore, it is no longer necessary to resort to manual operations for improving the surface of the cast article, as was heretofore necessary.
  • FIG. is a diagrammatic illustration of an apparatus for carrying out my novel method.
  • reference numeral 1 identifies a container which may be entirely of conventional construction, but which is provided, in accordance with the present invention, with a gas-permeable bottom wall 2. Below the bottom wall 2, wall means provides a pressure equalization chamber 3 with which the container 1 is rigidly connected via flanges 4. The purpose of the chamber 3 is to distribute the incoming gaseous fluid before it can enter through the gas-permeable bottom wall 2 into the interior of the container 1.
  • An outer shield 8 surrounds the container 1 and the chamber 3 and is configurated to catch any granular material which may be expelled from the container 1 on undergoing agitation as a result of admission of gaseous fluid.
  • the outer shield actually consists of a socket 7 and an upper portion 8, the latter being seated on the socket 7 and being provided .with suitable handles 9 whereby it can be lifted off from the socket 7.
  • a source of gaseous fluid is provided, identified in the drawing diagrammatically and with a legend, and it is connected with a conduit 5a to a conduit 5 which in turn communicates with the interior of the chamber 3.
  • a suitable valve is interposed between the conduits 5 and 5a and can be opened and closed depending on whether gaseous fluid is to be admitted into the chamber 3 whether such admission is to be terminated.
  • I additionally provide a source of vacuum, also diagrammatically illustrated and provided with a legend, and also communicating with a conduit 5a which in turn communicates with a conduit 5.
  • a three-way valve 6 of known construction which is operable in suitable manner, for instance via a foot pedal 6a, so as to selectively connect the conduit 5 with one of the conduits 5a, either the one leading to the source of vacuum or the source of gaseous fluid, the selection being determined by pressure on the foot pedal 6a and this determination in turn being made by an operator.
  • a source of gaseous fluid and a source of vacuum will be discussed subsequently.
  • the consumable mold is identified with reference numeral CF shown outside the container 1 ready to be introduced thereinto.
  • This consumable mold is of any type already well known in the art.
  • a casting means CM is provided for introducing molten metal into the consumable mold when the same is introduced into the container 1 and embedded therein into the body of granular material which is contained in the container 1 but not illustrated except for the dotted indication of granular material.
  • the body of granular material which may be sand or a high-heat-resistant granular material such as zirconium dioxide or an analogous material, or which may be sand mixed with zirconium dioxide or a similar material, is introduced first into the container 1.
  • a binder material may or may not be added but will advantageously be present in the case of large castings or castings which are tall.
  • the casting form CF may consist, as already pointed out, of a material which is consumed on contact with the molten metal, for instance foamed polystyrol, and will contain all of the features necessary for casting and well known to those skilled in the art.
  • the conduit 5 is connected with the conduit 5a leading to the source of gaseous fluid such as compressed air.
  • gaseous fluid such as compressed air.
  • Introduction of the gaseous fluid through the gas-permeable bottom wall 2 of the container 1 results in strong agitation of the granular material therein, approaching or even reaching a state of fluidization.
  • the casting form CF is slowly introduced into the thus agitated granular material until it reaches the desired position. This requires only a slight pressure upon the casting form CF and thus eliminates the possibility of damage to the same.
  • the agitated granular material swirls around the casting form CF as would a liquid, but despite this the casting form is not lifted if it is properly handled.
  • the admission of gaseous fluid is discontinued, preferably slowly and in stages to thereby obtain settling and compacting of the granular material about the casting form CF.
  • the form is now tightly and completely embedded in the material which surrounds it on all sides in firm engagement.
  • the molten metal is introduced via the casting means CM and this is not illustrated in detail because it is entirely conventional and well known to those skilled in the art.
  • the molten metal enters the casting form CF, it consumes the material thereof in known manner.
  • the form consists of foamed or expanded polystyrol, the polystyrol will collapse.
  • gaseous fluid is again admitted into the container 1 through the bottom wall 2 thereof, again placing the granular material into a state of near or complete fluidization and making it possible to readily and without any difficulty remove the cast article.
  • the casting process can be repeated any desired number of times without any necessity for changing the granular material.
  • my present method is particularly advantageous for continuous casting with the time intervals between each casting occurrence being determined only by the period required for cooling of the molten metal and solidification. If the casting form CF consists of a synthetic foam plastic material, then the time required for the granular material to cool must be taken into account because casting forms made from foamed plastic materials should not be used at temperatures in excess of approximately 80 C.
  • the present invention is very well suited for mechanization of the casting procedure.
  • the valve 6 is operated, as already shown in the drawing, with a foot pedal, although a different type of operation is possible.
  • the foot pedal operation is preferred because this leaves both hands of the operator free and makes it possible for him to service several apparatuses at the same time, thereby again increasing the economic feasibility of the method.
  • loose forming or casting sand may be used as the granular material in the container 1. This is generally preferable particularly where small and medium size workpieces are to be cast.
  • highly heat and combustion-resistant materials such as zirconium dioxide materials or the like or a loose casting sand mixed therewith, may be used where necessary or desired and particularly good results are then obtained.
  • zirconium dioxide materials or the like or a loose casting sand mixed therewith may be used where necessary or desired and particularly good results are then obtained.
  • auxiliary components such as casting funnels of consumable material for introducing the molten metal into the casting form, may also be embedded in the granular material in the same manner as the casting form, with requisite portions of such auxiliary elements being exposed, such as the inlet ofa casting funnel.
  • a method of making castings comprising the steps of confining a body of granular material in a container; initially admitting into a bottom region of said container a stream of gaseous fluid requisite for agitating said granular material and for imparting to said body a state at least approaching fluidization; introducing into the thus agitated granular material a form consisting of a material subject to consumption on contact with a molten metal; terminating admission of said gaseous fluid to thereby permit settling of the granular material about and into contact with said form; admitting molten metal into said form whereby the metal assumes the configuration of the same while simultaneously consuming the form; and again admitting gaseous fluid into said bottom region of said container to agitate said granular material for facilitating removal of the finished casting therefrom.
  • a method as defined in claim 1, the steps of initially and again admitting gaseous fluid comprising admitting such gaseous fluid in such a manner as to fluidize said granular material.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Casting Devices For Molds (AREA)
  • Producing Shaped Articles From Materials (AREA)
US795570*A 1968-02-03 1969-01-31 Method for making castings Expired - Lifetime US3581802A (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
DE1608046 1968-02-03

Publications (1)

Publication Number Publication Date
US3581802A true US3581802A (en) 1971-06-01

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US795570*A Expired - Lifetime US3581802A (en) 1968-02-03 1969-01-31 Method for making castings

Country Status (6)

Country Link
US (1) US3581802A (enrdf_load_stackoverflow)
CH (1) CH502861A (enrdf_load_stackoverflow)
DK (1) DK124460B (enrdf_load_stackoverflow)
FR (1) FR2001291A1 (enrdf_load_stackoverflow)
GB (1) GB1254592A (enrdf_load_stackoverflow)
SE (1) SE343493B (enrdf_load_stackoverflow)

Cited By (15)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3861447A (en) * 1971-12-14 1975-01-21 Akita Kk Molding method
US3868986A (en) * 1974-01-04 1975-03-04 Ford Motor Co Pattern alignment means for use with lost foam molding process
US4036276A (en) * 1974-09-30 1977-07-19 Mitsubishi Jukogyo Kabushiki Kaisha Method of shaping a mould under a reduced pressure
US4197899A (en) * 1976-12-22 1980-04-15 Ford Motor Company Method of casting a low weight reciprocating engine
US4222429A (en) * 1979-06-05 1980-09-16 Foundry Management, Inc. Foundry process including heat treating of produced castings in formation sand
US4249889A (en) * 1979-06-05 1981-02-10 Kemp Willard E Method and apparatus for preheating, positioning and holding objects
US4338878A (en) * 1980-11-26 1982-07-13 United Technologies Corporation Fluidized bed with sloped aperture plate
US4544013A (en) * 1983-11-07 1985-10-01 Ford Motor Company Method of reclaiming sand used in evaporative casting process
US4768567A (en) * 1987-09-03 1988-09-06 General Motors Corporation Sand fill apparatus for lost foam casting
US4874029A (en) * 1988-05-09 1989-10-17 General Motors Corporation Countergravity casting process and apparatus using destructible patterns suspended in an inherently unstable mass of particulate mold material
US4947923A (en) * 1988-04-14 1990-08-14 Rikker Leslie D Method and apparatus for evaporative pattern casting
US4957153A (en) * 1989-05-02 1990-09-18 General Motors Corporation Countergravity casting apparatus and method
US4969505A (en) * 1989-12-21 1990-11-13 General Motors Corporation Vacuum bore chill for lost foam casting
US4971131A (en) * 1989-08-28 1990-11-20 General Motors Corporation Countergravity casting using particulate filled vacuum chambers
US11014292B2 (en) * 2018-09-17 2021-05-25 Caterpillar Inc. Hybrid methods of additive manufacturing

Families Citing this family (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1397821A (en) * 1971-04-27 1975-06-18 Akita Kk Moulding method and apparatus
DE2519463A1 (de) * 1975-05-02 1976-11-11 Gruenzweig Hartmann Glasfaser Giessform und verfahren zur herstellung von gusstuecken
ZA817886B (en) * 1980-11-21 1982-10-27 Steel Castings Res Method of casting using expendable patterns
FR2523008A1 (fr) * 1982-03-11 1983-09-16 Citroen Sa Procede de moulage en modele perdu
FR2540761A1 (fr) * 1983-02-15 1984-08-17 Citroen Sa Installation pour le moulage en modele perdu

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2660770A (en) * 1950-09-06 1953-12-01 Walworth Co Casting apparatus
US2815550A (en) * 1954-08-03 1957-12-10 Bachner Valyi Dev Corp Method and apparatus for making foundry molds
US2985929A (en) * 1959-12-18 1961-05-30 Richard T Carter Method and apparatus for support and cooling of shell molds
US3010852A (en) * 1958-06-10 1961-11-28 Howe Sound Co Eliminating patterns from molds
US3222738A (en) * 1963-04-18 1965-12-14 Richard T Carter Methods of removing expendable plastic patterns

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2660770A (en) * 1950-09-06 1953-12-01 Walworth Co Casting apparatus
US2815550A (en) * 1954-08-03 1957-12-10 Bachner Valyi Dev Corp Method and apparatus for making foundry molds
US3010852A (en) * 1958-06-10 1961-11-28 Howe Sound Co Eliminating patterns from molds
US2985929A (en) * 1959-12-18 1961-05-30 Richard T Carter Method and apparatus for support and cooling of shell molds
US3222738A (en) * 1963-04-18 1965-12-14 Richard T Carter Methods of removing expendable plastic patterns

Cited By (15)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3861447A (en) * 1971-12-14 1975-01-21 Akita Kk Molding method
US3868986A (en) * 1974-01-04 1975-03-04 Ford Motor Co Pattern alignment means for use with lost foam molding process
US4036276A (en) * 1974-09-30 1977-07-19 Mitsubishi Jukogyo Kabushiki Kaisha Method of shaping a mould under a reduced pressure
US4197899A (en) * 1976-12-22 1980-04-15 Ford Motor Company Method of casting a low weight reciprocating engine
US4222429A (en) * 1979-06-05 1980-09-16 Foundry Management, Inc. Foundry process including heat treating of produced castings in formation sand
US4249889A (en) * 1979-06-05 1981-02-10 Kemp Willard E Method and apparatus for preheating, positioning and holding objects
US4338878A (en) * 1980-11-26 1982-07-13 United Technologies Corporation Fluidized bed with sloped aperture plate
US4544013A (en) * 1983-11-07 1985-10-01 Ford Motor Company Method of reclaiming sand used in evaporative casting process
US4768567A (en) * 1987-09-03 1988-09-06 General Motors Corporation Sand fill apparatus for lost foam casting
US4947923A (en) * 1988-04-14 1990-08-14 Rikker Leslie D Method and apparatus for evaporative pattern casting
US4874029A (en) * 1988-05-09 1989-10-17 General Motors Corporation Countergravity casting process and apparatus using destructible patterns suspended in an inherently unstable mass of particulate mold material
US4957153A (en) * 1989-05-02 1990-09-18 General Motors Corporation Countergravity casting apparatus and method
US4971131A (en) * 1989-08-28 1990-11-20 General Motors Corporation Countergravity casting using particulate filled vacuum chambers
US4969505A (en) * 1989-12-21 1990-11-13 General Motors Corporation Vacuum bore chill for lost foam casting
US11014292B2 (en) * 2018-09-17 2021-05-25 Caterpillar Inc. Hybrid methods of additive manufacturing

Also Published As

Publication number Publication date
SE343493B (enrdf_load_stackoverflow) 1972-03-13
CH502861A (de) 1971-02-15
FR2001291A1 (enrdf_load_stackoverflow) 1969-09-26
DK124460B (da) 1972-10-23
GB1254592A (en) 1971-11-24

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