Gm Global Technolgoy Operations, Inc.

General Motors LLC

David Douglas Goettsch

Jason R Traub

Brad A Ohlrich

Michael J Walker

Anil Kumar Sachdev

Bob Ross Powell

Maurice G Meyer

Christopher D Cogan

Garrold A DeGrace

James T Singer

Stephen M Fitch

Mark Eugene Hoover

Gregory T Naismith

Allen T Birschbach

Madhusudhan Raju Nannapuraju

Kyle W Lehrmann

A modular casting mold for casting an automotive component includes a plurality of die portions defining a mold cavity corresponding to an automotive component, at least one of the plurality of die portions is an active die portion adapted to control the temperature of the modular casting mold throughout the casting process and including features for ejecting an automotive component cast within the modular casting mold, and the modular casting mold adapted to be attached to another modular casting mold for casting a single automotive component.

Modular mold design for casting a vehicle frame and components

A method for casting metal using a semi-permanent mold connected to a feed portion includes forming a coolant jacket in a sprue of the feed portion. A coolant source is connected to the coolant jacket. A metal in a molten state is poured into the feed portion for gravity induced flow into the semi-permanent mold. A wall thickness of the sprue is predetermining which minimizes heat transfer from the sprue, thereby forcing the metal in the molten state to cool slower in the sprue than in the mold. After a predetermined time for the metal to cool to a solid state in the mold, flow of a coolant from the coolant source into the coolant jacket is initiated to cool the metal in the sprue before opening the mold.

Method for the semi-permanent mold casting process

A device and method for transferring filtered molten metal to a die casting mold. The device and method include a casting filtration system that includes a funnel and a continuously replaceable filter placed fluidly between a molten metal source and a casting mold. Both the funnel and filter are automatically moved into cooperation with a molten metal receptacle such as a shot sleeve prior to each casting operation, and then automatically moved out of the way so that pressurization of the filtered molten metal may take place in the receptacle. In addition, the filter may be formed on a continuous strand such that indexed movement of the strand will advance the used portion of the filter out of the way to make room for a new unused filter portion that will be ready for a subsequent repeated casting operation.

Device and method for filtering molten metal

A method of transferring molten metal to a die casting mold is disclosed. The method includes providing a ladle with a dip well and a dispensing nozzle having a fluid metal filter formed therein as well as providing a receptacle fluidly between the ladle and the mold. Further the method includes delivering the molten metal from the ladle to the receptacle by positioning an exit face of the dispensing nozzle over the receptacle and rotating the ladle such that the exit face of the dispensing nozzle is repositioned proximal the bottom of the receptacle and conveying the molten metal that has been delivered to the receptacle into a mold cavity that is placed in fluid communication therewith.

Metal pouring method for the die casting process

Methods, systems, and apparatus for reduction of gas pressure within a core, such as a sand casting core package, during a casting process in order to reduce bubble defects. Some embodiments may comprise a mold configured to receive a molten metal to create a metal casting, such as an engine block casting. The mold may comprise a mold core configured to create a cavity within the metal casting. The system may further comprise a filling device configured for delivering a molten metal into the mold for creating the metal casting. The mold core may comprise a material that is permeable to certain gases known to often result in bubble defects. The system may further comprise a vacuum configured to be coupled with the mold to reduce gas pressure within a permeable portion of the mold in order to reduce the incidence of bubble defects within the casting.

Methods for sand core gas evacuation and related systems and apparatus

A method for delivering molten metal from a ladle to a die casting shot sleeve and a ladle and shot sleeve assembly. Both the ladle and a rotatable device coupled to the shot sleeve are made to rotate about respective axes as a way to reduce air entrainment and oxide film inclusions during the gravity filling of the shot sleeve with molten metal from the ladle. In a preferred form, the axis of rotation of the nozzle in the ladle is orthogonal to the axis of rotation of the shot sleeve rotatable device that is preferably placed in a horizontal filling direction. The nozzle is configured to deliver the molten metal through the lowest level of the shot sleeve when the ladle is rotated from a first position to a second position about its axis, followed by its rotation about a filling axis of the shot sleeve from a first angular position to a second angular position. At the second angular position, a die casting plunger can fill the casting cavity with the molten metal that has been delivered to the shot sleeve.

A ladle for a molten metal includes a main body having a hollow interior and an opening for receiving the molten metal. The main body has a sidewall with a nozzle formed therein. The nozzle defines an axis of rotation for the main body. The nozzle contacts, seals and is in fluid communication with the mold. The nozzle is configured to deliver the molten metal to a mold when the main body is rotated from a first position to a second position.

Ladle for molten metal

An apparatus and method for quiescently filling of a ladle with molten material and transferring of the molten material from the ladle is disclosed, wherein the molten material is transferred from the ladle to a casting mold to minimize turbulence in the molten material to minimize defects in a desired cast object.

A cooling chamber design that increases the heat transfer over conventional designs during the casting process of an aluminum cylinder head.

Combustion chamber wall cooling chamber design for semi-permanent mold cylinder head casting

A method and apparatus is disclosed for forming a metal casting sprue for a lost foam casting process, the sprue formed in sand for receiving molten metal and directing the molten metal to a foam pattern in a mold cavity, wherein the sprue formation is facilitated by an insert having a plurality of apertures formed therein, the apertures facilitating an application of a coating to sand surrounding the insert prior to removal of the insert from the sand, and wherein the sprue facilitates a minimization of production costs and an optimization of material properties of the resultant casting.

Lost foam casting apparatus and method for creating hollow gating

Method of making a subcutaneous melt flow-channel in the surface of a fugitive foam pattern used in lost-foam casting process. After a refractory skin has been formed on the surface of a foam pattern, a strip of the skin is treated so as to cause the foam underlying the strip to recede from the strip and leave a groove in its stead. Suitable treatments include () heating the strip, or () applying a foam solvent thereto that soaks through the skin. In each case, the treatment is such as to cause the foam underlying the treated strip to soften and recede from the strip.

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Shelby Township, MI, United States of America

David Douglas Goettsch