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Metal Casting System, Engineered Molds, Process and Articles Made Thereby

  • US 20080308249A1
  • Filed: 01/03/2007
  • Published: 12/18/2008
  • Est. Priority Date: 01/03/2006
  • Status: Active Grant
First Claim
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1. A metal casting system (1) for continuous delivery of molten metal in a controlled environment, comprising:

  • a melting furnace (2) having a molten metal surface and an inert furnace atmosphere throughout the entire casting system, wherein said inert furnace atmosphere is inert to the metal being cast;

    a pressurized metal delivery vessel (12) connected to the melting furnace (2) with a discharge opening dam (6) for maintaining a production level (4) of molten metal to continuously deliver clean, oxide-free metal from below the molten metal surface;

    a treatment vessel (5) connected between the melting furnace and the metal delivery vessel to provide a continuous supply of molten metal from the melting furnace to the metal delivery vessel;

    a transfer valve (9) that allows metal flow from the melting furnace to the metal delivery vessel; and

    an engineered sand mold for receiving molten metal from the pressurized metal delivery vessel, wherein said engineered sand mold is at least partially encapsulated to contain a significantly reduced amount of sand in the sand mold and facilitating maintenance of a controlled atmosphere with inert gases.

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