Ford Motor Company Limited

Adolf Hetke

Prem P Mohla

Robert J Warrick

Walter J Evans

Kip M Bonds

A method of treating molten metals is disclosed which employs a solid sheathless flexible strand containing particles of the treating agent uniformly suspended in a binder matrix, the latter being consumable or vaporizable upon contact with molten metal. Positive and predetermined solution conditions of the treating agent are assured by regulating the molten metal flow velocity to be at or above a predetermined minimum and the strand injection rate to be within defined limits.

Sheathed wire feeding of alloy and inoculant materials

A pattern destructible on contact with a molten metal charge is given a composite coating consisting of a (1) highly tacky viscous adhesive substantially devoid of solids and having a low gas content, (2) a collection of ultra-fine refractory paticles (carbon facing sand) aligned on the surface of said adhesive. The adhesive volatilizes on contact with the casting charge while the refractory particles remain unaffected. An ultra-smooth cast surface is produced without macro crevices inherent in the surface of a destructible pattern and the mold sand is reusable without contamination by a high portion of burned sand.

Coating for gasifiable foam patterns

Sheathless wire feeding of alloy and inoculant materials

An improved catalyst is disclosed for making spheroidal graphite cast iron, the catalyst being in the form of a solid impervious and brittle block but severed from a sheet stock having a predetermined grid pattern of perforations or notches along at least one surface of said sheet stock. The block is substantially devoid of segregation and oxide interiorally thereof; the thickness of said block is increased over that capable of being produced by the prior art in the as-cast condition and yet devoid of segregation. The method of making such block comprises casting the molten catalyst into shallow closed pans, the cover for said pans carrying a pattern of ribs or projections, the cover and pan cooperating to define a selected configuration for an as-cast sheet stock. The resulting cast product can be manually or automatically broken along any desired module, defined by said grid pattern, to suit a variety of in plant casting applications particularly utilizing in-the-mold nodularizing treatment. The latter method places a nodularizing catalyst in a recess or reaction chamber defined within the gating system of a mold, whether constructed of bonded sand or pre-cast refractory.

Nodularizing catalyst for cast iron and method of making same

A method and apparatus is disclosed for conditioning a charge of molten cast iron, which would normally solidify with a flake graphite structure, to produce partial or total spheroidal graphite cast iron. In addition, the method and apparatus can be used to further condition a partially conditioned cast iron to yield a partial or fully spheroidal graphite cast iron. A recess is provided in the metal flow system (within or without the mold system) leading to the casting cavity or cavities. The recess has a shape and cross-section (taken in directions normal to the direction of flow of the molten charge) such that the spheroidizing agent dissolves uniformly when the molten iron flows over it to achieve unprecedented homogeneity. A dense solid unitary block of spheroidizing or nodularizing agent, substantially devoid of MgO interiorly thereof, is typically snugly fitted in said recess and mates with the side walls and bottom of said recess. The block typically presents a substantially constant and uniform interface with the molten charge during all stages of conditioning and pouring; however, a deviation in the interface area may be designed into the block to compensate for molten iron temperature variations or molten iron flow rate variations when the casting technique experiences unusually high variations in the ferrostatic pressure head. A relationship is disclosed between charge weight, charge flow rate, magnesium concentration in the spheroidizing alloy, and interface area so as to determine a desired degree of nodularity in the final casting and/or to design a solution rate compatible with a specific casting technique. The residual magnesium can be reliably maintained at a level sufficient to consistently obtain full spheroidal graphite shape. A preferred magnesium level is 0.020% to 0.040% of the weight of the casting but higher or lower levels can be reliably obtained if required by base metal chemistry. This is significant since the prior art has been unable to reliably obtain full nodularity with 0.02-0.025% residual magnesium under commercial conditions.

Nodularizing treatment employing unitized modifying agent

A method of making aluminum castings having a self-fused high silicon content in the interior matrix near and at the surface. A sand core is coated with a tacky, low-ash, low-volatile adhesive along a predetermined zone. Silicon dust particles are deposited on said adhesive in bonded relation. Molten aluminum is cast into a mold cavity containing the coated core. After mold stripping, the silicon particles are exposed as metallurgically bonded to the aluminum but along an ultra-thin depth. At least some of the exposed silicon particles are machined to expose a planar facet and thereby increase the projected exposure of the silicon particles along the machined plane. The resulting product has a reduced shrinkage characteristic (typical of aluminum alloys having a high proportional precipitated silicon).

Method of aluminum cylinder head valve seat coating transplant

Aluminum cylinder head valve seat coating transplant

A pattern destructible on contact with a molten metal charge is given a composite coating consisting of a highly tacky viscous adhesive substantially devoid of solids and single particle thickness layer collection of ultra-fine refractory particles (carbon facing sand) aligned on the surface of said adhesive. The adhesive volatilizes on contact with the casting charge while the refractory particles remain unaffected. An ultra-smooth cast surface is produced without macro crevices inherent in the surface of a destructible pattern and the mold sand is reusable without contamination by a high portion of burned sand.

Method for cavityless casting employing a dual layer pattern coating

A method of making a more economical and reliable treating agent for use in late metal treatment when pouring metal castings. The treating agent is defined as an essentially homogeneous solid cast block preferably containing alloying ingredients to nodulize or inoculant ferrous metal. Each block is designed to present a generally uniform reaction surface to molten metal to be treated. This is obtained by casting the block to a shape which snugly fits a prepared basin in the mold gating system over which the molten metal to be treated must flow, or to cast the block in an annular configuration through which the molten metal must flow. The latter block has contoured inner surfaces which maintain a generally constant reactive surface as the block is consumed. These blocks are preferably prepared by simultaneously casting a large number in closely nested relation. Each mold for said blocks receives molten material, out of which the agent is formed, from a common sprue; runners interconnect the mold cavities and sprue, for example, in a simulated 'Christmas tree' arrangement. The gating system and mold cavity pattern, for casting the treating agent to a special shape are all comprised of a material that will vaporize upon contact by the molten treating agent, such as polystyrene. The unitary tree structure of foam patterns and gating system is placed in a flask and surrounded by unbonded heat absorbing particles, such as sand or steel shot. Rapid solidification is assured by the selection of heat absorbing particles and by the use of the vaporizable patterns to avoid noticeable segregation in the alloy blocks. The blocks formed for the treating agent are characterized by increased homogeneity, absence of undesirable segregation, absence of internal oxidation, and absence of organic or refractory impurities; the blocks are less costly to make both as to capital requirements and operating expenses.

Growing community of inventors

Livonia, MI, United States of America

Adolf Hetke