Metal casting unit

• US 5,318,098 A
• Filed: 09/24/1992
• Issued: 06/07/1994
• Est. Priority Date: 09/24/1992
• Status: Expired due to Term

• Current Assignee: Wagstaff Incorporated
• Original Assignee: Wagstaff Incorporated
• Inventors: Wagstaff, Frank E., Fort, David A., Wagstaff, Robert B., Collins, Richard J.
• Primary Examiner(s): Bradley, Paula A.
• Assistant Examiner(s): PUKNYS, ERIK
• Application Number:
  US07/950,148
• Time in Patent Office: 621 Days
• Field of Search: 164/487, 164/486, 164/444, 164/443, 164/451, 164/458, 164/4.1, 164/150, 164/414
• US Class Current: 164/444
• CPC Class Codes: B22D 11/049 for direct chill casting, e.g. electromagnetic casting

Abstract

A casting unit 6 consists of a monolithic body which is annular in shape and has an annular flange 72 outturned about the axis and monolithically outstanding on the body at the outer periphery, a set of lugs 110 angularly spaced about the axis on the lower end portion of the body and monolithically outstanding in the aperture, and a circumferential groove 114 about the outer periphery of the body in the upper end portion, with mullions 20 monolithically upstanding therein, adjacent the outer periphery of the groove, to form ports 112.The groove is interconnected with the cavity 108 in the lower end portion of the body at the aperture; and passages, 126, 140, a graphite ring 16, and whatever else is required, are added to complete the unit 6 before it is supported in an aperture in a metal casting table 2, having liquid coolant discharge means 14 circumposed thereabout and a stool to support molten metal after being mated with the lugs. Where the liquid coolant discharge means take the form of a liquid coolant box, the housing 22, 24 of which defines the table, and the casting unit is upwardly inserted in the box, at an aperture 26 in the bottom, and abutted with the top of the chamber 14, a device 17 is provided for sensing leakage between the casting unit and the top of the chamber. The leakage is discharged in a passage 140 passing through one of the mullions to the bottom of the casting unit.

Claims

1. In a molten metal casting apparatus of the type wherein an annular metal casting unit is supported in an aperture in a casting table to form an open ended metal casting station thereon through which the molten metal to be cast is poured along a vertical axis of the table and cast into a molten metal body, and wherein during the casting procedure, the casting station has a stool operatively disposed therebelow on the axis of the table to telescopically engage with the bottom of the casting unit at a stage preliminary to the casting operation, and then in the operation itself, to provide a relatively retractable support for the molten metal body as it progressively emerges from the unit and elongates along the axis of the table, and wherein moreover, the metal casting unit has an opening formed therein about the molten metal body, and means formed thereabout in the apparatus for discharging liquid coolant through the opening to direct cool the molten metal body as it emerges from the unit and elongates along the axis of the table,

the improvement wherein

the metal casting unit comprises an annular mold which is formed as a monolithic body of mold forming material having a vertical axis, upper and lower ends, an aperture between the ends thereof on the mold body axis, and an annular flange which is relatively outturned about the mold body axis, and monolithically outstanding in the same material at the outer periphery of the mold body,

the mold body is telescopically inserted in the aperture of the table coaxially thereof, to form the casting station, and is abutted against the table at the flange thereof, to receive support from the table,

the mold body has angularly spaced guide means about the axis thereof, which are monolithically outstanding in the same material on the lower end portion of the mold body in the aperture thereof, to mate with the stool in the stage preliminary to the casting operation,

the mold body has angularly spaced ports about the axis thereof, which are recessed in the outer periphery of the mold body to interface with the liquid coolant discharge means, and to open into the aperture of the mold body between the guide means and the upper end portion of the mold body during the casting operation, so that the liquid coolant discharges through the ports into the lower end portion of the mold body to direct cool the molten metal body as it emerges from the upper end portion of the mold body and elongates along the axis thereof, and

the mold body is engaged with the table in an annulus about the axis of the table, the annulus has a fluid supply connection thereacross between the mold body and the table, and the mold body has an additional opening in one end portion thereof, and a fluid flow passage therewithin which is interconnected between the fluid supply connection and the additional opening to transmit fluid to the additional opening from the connection for discharge from the mold body, relatively outside thereof.

2. The molten metal casting apparatus according to claim 1 wherein the annulus is formed about the axis of the table at the abutment interface between the flange and the table.

3. The molten metal casting apparatus according to claim 1 wherein the ports are defined by outer peripheral portions of the mold body which monolithically upstand in the same material between the upper and lower end portions of the mold body, generally axially thereof, and the fluid flow passage extends through one of the port defining outer peripheral portions of the mold body, axially thereof.

4. The molten metal casting apparatus according to claim 1 wherein the mold body has an annular rabbet about the inner periphery thereof at the upper end thereof, the additional opening is formed in the axially extending wall of the rabbet, and the metal casting unit further comprises a ring of graphite or the like which is seated in the rabbet so that the fluid transmitted through the passage can be forced therethrough in the direction of the axis of the mold body, to form an annulus of fluid about the molten metal body as it is cast within the aperture of the mold body.

5. The molten metal casting apparatus according to claim 1 wherein the liquid coolant discharge means take the form of a liquid coolant box, the housing of which defines the table and has spaced top and bottom housing members therein, which in turn have a pair of mutually opposing top and bottom apertures therein about a vertical axis of the box, and a chamber in the space between the members for supplying liquid coolant to the casting unit, and wherein the flange is monolithically outstanding in the same material on one end portion of the mold body at the outer periphery thereof, the mold body is telescopically inserted in the chamber through the aperture in one of the housing members, and abutted against the one housing member at the flange thereof, and against the other housing member about the aperture therein, so that in forming the casting station, the mold body interfaces with the chamber at the ports in the outer periphery thereof, for the discharge of the chamber coolant therethrough.

6. The molten metal casting apparatus according to claim 5 wherein the flange is monolithically outstanding in the same material on the lower end portion of the mold body at the outer periphery thereof, the mold body is telescopically inserted in the chamber through the bottom aperture of the box, and abutted against the bottom housing member at the flange thereof, and against the top housing member at the upper end portion thereof, and the fluid supply connection is formed in the abutment interface between the upper end portion of the mold body and the top housing member of the box.

7. The molten metal casting apparatus according to claim 6 wherein the additional opening is formed in the lower end portion of the mold body, and the abutment interface between the upper end portion of the mold body and the top housing member of the box has a pair of annular seals formed thereabout in circumferentially extending lines of the interface which are relatively radially spaced apart from one another about the axis of the box and relatively offset from one another axially of the box, with the fluid supply connection interposed therebetween to intercept any liquid coolant which leaks from the chamber past the relatively radially outer seal of the interface in the direction of the axis of the box, and discharge the leakage coolant in the direction of the additional opening before the leakage coolant can penetrate the relatively inner seal of the interface.

8. The molten metal casting apparatus according to claim 7 wherein the mold body has an annular rabbet about the outer periphery thereof at the upper end thereof, to form a pair of annular shoulders about the rabbet and the upper end of the mold body, and the top housing member of the box has an annular seal of elastomeric material circumposed about the axis thereof adjacent the top aperture therein, which is engaged with the annular shoulders about the rabbet and the upper end of the mold body, to form the pair of annular seals about the interface between the upper end portion of the mold body and the top housing member of the box, the elastomeric seal having an annular swale about the inner periphery thereof, at the lower end thereof, to leave an annular clearance between the elastomeric seal and the step of the rabbet, and the fluid supply connection being formed in the step of the rabbet opposite the swale to intercept liquid coolant which leaks across the seal between the elastomeric seal and the shoulder of the rabbet, before the leakage can penetrate the seal between the elastomeric seal and the shoulder on the upper end of the mold body.

9. The molten metal casting apparatus according to claim 5 wherein the box has an annular screen circumposed about the axis thereof at the outer periphery of the casting station, to screen the liquid coolant discharging through the ports of the mold body from the chamber of the box.

10. The molten metal casting apparatus according to claim 5 wherein the metal casting unit further comprises an annular baffle which is sleeved about the series of ports in the mold body and has a series of holes symmetrically arrayed thereabout to meter the coolant flow into the ports from the chamber.

11. In a molten metal casting apparatus of the type wherein an annular metal casting unit is supported in an aperture in a casting table to form an open ended metal casting station thereon through which the molten metal to be cast is poured along a vertical axis of the table and cast into a molten metal body, and wherein during the casting procedure, the casting station has a stool operatively disposed therebelow on the axis of the table to telescopically engage with the bottom of the casting unit at a stage preliminary to the casting operation, and then in the operation itself, to provide a relatively retractable support for the molten metal body as it progressively emerges from the unit and elongates along the axis of the table, and wherein moreover, the metal casting unit has an opening formed therein about the molten metal body, and means formed thereabout in the apparatus for discharging liquid coolant through the opening to direct cool the molten metal body as it emerges from the unit and elongates along the axis of the table,

the improvement wherein

the metal casting unit comprises an annular mold which is formed as a monolithic body of mold forming material having a vertical axis, upper and lower ends, an aperture between the ends thereof on the mold body axis, and an annular flange which is relatively outturned about the mold body axis, and monolithically outstanding in the same material at the outer periphery of the mold body,

the mold body is telescopically inserted in the aperture of the table coaxially thereof, to form the casting station, and is abutted against the table at the flange thereof, to receive support from the table,

the mold body has annular surfaces extending about the axis thereof at the inner peripheries of the upper and lower end portions of the mold body, respectively, which define an open ended upper cavity in the aperture thereof, having a cross sectional configuration in first planes transverse the axis of the mold body corresponding to the cross sectional configuration of the molten metal body to be cast therein, and an open ended lower cavity in the aperture of the mold body, having a cross sectional configuration in second planes transverse the axis of the mold body corresponding to the cross sectional configuration of the upper cavity, but greater in cross sectional area than that of the upper cavity in each of said second planes so as to provide an annulus of open air about the molten metal body as it emerges from the upper cavity and elongates along the axis of the mold body in the lower cavity,

the mold body has guide means which are angularly spaced about the axis thereof, and monolithically outstanding in the same material on the lower end portion of the mold body in the lower cavity of the aperture therein, to mate with the stool in the stage preliminary to the casting operation,

the mold body has a series of closely spaced holes in the inner peripheral portion thereof, which are generally symmetrically arrayed about the axis of the mold body to terminate at the inner periphery thereof and open into the lower cavity in the aperture of the mold body between the guide means and the upper cavity in the aperture of the mold body,

the mold body has an annular passage therein which extends about the axis of the mold body and opens into the series of holes, and

the mold body has a series of angularly spaced ports arrayed about the axis thereof, which are recessed in the mold body at the outer periphery thereof to interface with the liquid coolant discharge means, and which open into the annular passage in the mold body to discharge the liquid coolant into the annulus through the series of holes and direct cool the molten metal body when it has emerged from the upper cavity in the aperture of the mold body and is elongating along the axis thereof.

12. The molten metal casting apparatus according to claim 11 wherein the mold body has an annular surface extending about the outer periphery thereof which interfaces with the liquid coolant discharge means, and a circumferential groove in said outer peripheral surface which has a series of mullions therein that are angularly spaced about the groove and axially upstanding therein of the same material, to form the ports, the mullions being radially outwardly spaced from the bottom of the groove, to leave an annular channel about the axis of the mold body between the mullions and the bottom of the groove, which channel opens into the series of holes in the inner peripheral portion of the mold body.

13. The molten metal casting apparatus according to claim 12 wherein the groove is formed in the upper end portion of the mold body and the series of holes is sharply angled downwardly therefrom in the general direction of the axis of the mold body.

14. The molten metal casting apparatus according to claim 11 wherein the mold body has a first annular surface extending about the outer periphery thereof which interfaces with the liquid coolant discharge means, and second and third annular surfaces which extend about the axis of the mold body at the inner peripheries of the upper and lower end portions of the mold body, respectively, the second of which annular surfaces extends generally parallel to the axis of the mold body and defines the open ended upper cavity in the aperture thereof, and the third of which annular surfaces defines the open ended lower cavity in the aperture of the mold body, the cross sectional configuration of the lower cavity in said second planes of the mold body flaring relatively outwardly from the axis of the mold body in the direction relatively toward the lower end thereof from the upper end thereof, to form a progressively enlarged annulus of open air about the molten metal body it emerges from the upper cavity and elongates along the axis of the mold body in the lower cavity, the guide means taking the form of a set of angularly spaced lugs which are monolithically outstanding on the third annular surface in the same material, to mate with the stool in the stage preliminary to the casting operation, and the series of ports being formed by a circumferential groove in the outer peripheral portion of the mold body at the first annular surface thereof, which has a series of mullions that are angularly spaced about the groove and axially upstanding therein of the same material, to form the ports.

15. The molten metal casting apparatus according to claim 14 wherein the mullions are radially outwardly spaced from the bottom of the groove, to leave an annular channel about the axis of the mold body between the mullions and the bottom of the groove, which opens into the series of holes.

16. The molten metal casting apparatus according to claim 15 wherein the groove is formed in the upper end portion of the mold body, and the series of holes is sharply angled downwardly therefrom in the general direction of the axis of the mold body.

17. The molten metal casting apparatus according to claim 14 wherein the first and second annular surfaces of the mold body are cylindrical, and the third annular surface thereof is comprised of an axially extending series of conical sections, the uppermost of which has the series of closely spaced holes opening therein, and the lowermost of which has the set of angularly spaced lugs monolithically outstanding thereon.

18. In a molten metal casting apparatus wherein an annular metal casting unit with an annular flange relatively outturned thereabout, is inserted in a liquid coolant box to form an open ended metal casting station about a vertical axis of the box, the box has top and bottom plate-like housing members, a chamber for the liquid coolant between the housing members, and mutually opposing top and bottom apertures in the members on the axis, the annular casting unit is telescopically inserted in the chamber through the bottom aperture in the box, abutted against the bottom housing member at the flange thereof, and engaged with the top housing member in an annulus about the top aperture therein, and means are provided in the annulus to provide a pair of annular seals thereabout in circumferentially extending lines of the annulus which are relatively radially spaced apart from one another about the axis of the box and relatively offset from one another axially of the box,

the improvement wherein:

the metal casting unit has an opening in the lower end portion thereof, a port in the upper end portion thereof which opens into the annulus between the annular seals formed thereabout, and a fluid flow passage therein which is interconnected between the port and the opening to discharge to the opening, liquid coolant that leaks from the chamber past the relatively radially outer seal of the annulus in the direction of the axis of the box, before the leakage coolant can penetrate the relatively radially inner seal of the annulus.

19. The metal casting apparatus according to claim 18 wherein that inner peripheral edge portion of the top housing member which defines the top aperture therein, forms a cover over the port, so that molten metal cannot penetrate the annulus and contaminate the metal casting unit.

20. The metal casting apparatus according to claim 18 wherein the metal casting unit has an annular rabbet about the outer periphery thereof, at the upper end thereof, to form a pair of annular shoulders about the rabbet and the upper end of the casting unit, and the top housing member of the box has an annular seal of elastomeric material circumposed about the axis thereof adjacent the top aperture therein, which engages with the annular shoulders about the rabbet and the upper end of the casting unit, to form a pair of annular seals about an annulus between the upper end portion of the casting unit and the top housing member of the box, and wherein the elastomeric seal has an annular swale about the inner periphery thereof, at the lower end thereof, to leave an annular clearance between the elastomeric seal and the step of the rabbet, and the port of the casting unit is formed in the step of the rabbet opposite the swale to intercept liquid coolant which leaks across the seal between the elastomeric seal and the shoulder of the rabbet, before the leakage can penetrate the seal between the elastomeric seal and the shoulder on the upper end of the casting unit.

21. The metal casting apparatus according to claim 18 further comprising leakage coolant detection means in the casting station for sensing the presence of leakage coolant flow in the passage of the casting unit, and communicating the same to an operator of the apparatus.

22. The metal casting apparatus according to claim 21 wherein the leakage coolant detection means include a leakage coolant receptacle which is mounted on the apparatus adjacent the casting station, and has a transparent window therein which is exposed relatively outside of the apparatus for viewing by an operator thereof, means which define a shunt in the passage for sidetracking a portion of the leakage coolant flow to the receptacle, and indicator means whereby the presence of the sidetracked portion of the leakage coolant flow in the receptacle is made visually apparent to the operator through the window of the receptacle.

23. The metal casting apparatus according to claim 22 wherein the indicator means include means of changeable color which are interactive with the sidetracked portion of the leakage coolant flow to change color in the window of the receptacle.

24. The metal casting apparatus according to claim 23 wherein the changeable color means are liquid coolant soluble, to dissolve in the sidetracked portion of the leakage coolant when interacting with the same.

25. The metal casting apparatus according to claim 22 wherein the receptacle has an axis, a bore of predetermined diameter with opposing ends which are disposed on the axis of the receptacle, and relatively proximal to and remote from the shunt, respectively, and a relatively reduced diameter throat which is disposed in the relatively remote end of the bore transverse the axis of the receptacle and opens onto the window of the receptacle, and wherein the proximal end of the bore is connected with the shunt to receive the sidetracked portion of the leakage coolant flow, and the indicator means are disposed in the bore and responsive to the presence of the sidetracked portion of the leakage coolant flow therein, to pass through the throat and appear at the window of the receptacle.

26. The metal casting apparatus according to claim 25 wherein the indicator means include means of changeable color which are interactive with the sidetracked portion of the leakage coolant flow, to pass through the throat and appear at the window of the receptacle with the flow.

27. The metal casting apparatus according to claim 26 wherein the changeable color means are liquid coolant soluble, to dissolve in the sidetracked portion of the flow when interacting therewith, and to flow through the throat with the sidetracked portion of the flow as an additive thereto.

28. The metal casting apparatus according to claim 25 wherein the receptacle has a portion thereof which projects relatively outside the apparatus on the axis of the receptacle, with the window therein for viewing by the operator of the apparatus, and the relatively projecting portion of the receptacle has a cavity therein on the opposite side of the throat from the bore to receive the indicator means when the same passes through the throat.

29. The metal casting apparatus according to claim 28 wherein the indicator means include a signaling device which is responsive to the presence of the sidetracked portion of the leakage flow in the bore, to pass through the throat and occupy the cavity of the receptacle for viewing by the operator through the window thereof.

30. The metal casting apparatus according to claim 25 wherein the receptacle has an end thereof which is exposed to the outside of the apparatus for viewing by the operator thereof, with the window therein, on the axis of the receptacle, the throat opens to atmosphere at the window of the receptacle, and the indicator means include a signaling device which is responsive to the presence of the sidetracked portion of the leakage coolant flow in the bore to project through the throat relatively outside the end of the receptacle at the window, for viewing by the operator.

31. The metal casting apparatus according to claim 25 wherein the indicator means include a signaling device which is movably disposed in the bore of the receptacle to pass through the throat in the direction of the window of the receptacle, and the leakage coolant detection means further comprise biasing means interposed between the signaling device and the proximal end of the bore, to urge the device along the axis of the receptacle in the direction of the window of the receptacle when the sidetracked portion of the leakage coolant flow is received in the bore, and restrainer means interposed between the signaling device and the remote end of the bore, to restrain the device from passing through the throat in the direction of the window of the receptacle when the bore is devoid of leakage, the restrainer means being soluble in the liquid coolant to dissolve therein when the leakage coolant flow is received in the bore, so that the biasing means can displace the signaling device along the axis of the receptacle to the extent that the device passes through the throat in the direction of the window of the receptacle.

32. The metal casting apparatus according to claim 31 wherein the receptacle has a portion thereof which projects relatively outside the apparatus on the axis of the receptacle, and on the opposite side of the throat from the bore, with a closed but transparent window therein for viewing by the operator of the apparatus, the relatively projecting portion of the receptacle has a cavity therein to receive the signaling device when the same passes through the throat, and the signaling device takes the form of a ball which is coated with a liquid coolant soluble material that operates to restrain it from passing through the throat when the bore is devoid of leakage coolant, but dissolves in the leakage coolant flow when the flow is received in the bore, to enable the ball to pass through the throat under the bias of the leakage coolant itself, and appear at the window of the receptacle in the cavity.

33. The metal casting apparatus according to claim 31 wherein the receptacle has an end thereof which is exposed to the outside of the apparatus on the axis of the receptacle, and on the opposite side of the throat from the bore, with the window therein for viewing by the operator of the apparatus, the throat opens to atmosphere at the window of the receptacle, the indicator means include a signaling device which is responsive to the presence of the sidetracked portion of the leakage coolant flow in the bore to project through the throat relatively outside the end of the receptacle at the window, for viewing by the operator, the signaling device takes the form of a piston which has a pin thereon that is disposed to project through the throat and appear at the window of the receptacle, and the leakage coolant detection means further comprise a spring caged between the piston and the proximal end of the bore, to urge the piston to pass the pin through the throat to the extent that the pin projects relatively outside the apparatus at the window of the receptacle, and a sleeve circumposed about the pin in the bore to restrain the piston from passing the pin through the throat to the aforesaid extent, the sleeve being soluble in the leakage coolant to dissolve and thereby allow the spring to displace the piston to the extent that the pin does pass through the throat and project relatively outside the apparatus at the window of the receptacle.

34. An annular mold for insertion in an aperture in a metal casting table to form an open ended molten metal casting station thereon through which the molten metal to be cast is poured along a vertical axis of the table and cast into a molten metal body, and wherein during the casting procedure, the casting station has a stool operatively disposed therebelow on the axis of the table to telescopically engage with the bottom of the mold at a stage preliminary to the casting operation, and then in the operation itself, to provide a relatively reciprocable support for the molten metal body as it progressively emerges from the mold and elongates along the axis of the table, and wherein moreover, the mold has an opening formed therein about the molten metal body, and means formed thereabout on the table for discharging liquid coolant through the opening to direct cool the molten metal body as it emerges from the mold and elongates along the axis of the table, comprising:

a monolithic body of mold forming material having a vertical axis, upper and lower ends, and an aperture between the ends thereof on the mold body axis,

the mold body having an annular flange which is relatively outturned about the mold body axis, and monolithically outstanding in the same material at the outer periphery of the mold body to abut the table and receive support therefrom when the mold is inserted in the aperture of the table coaxially thereof, to form the station,

the mold body having annular surfaces extending about the axis thereof at the inner peripheries of the upper and lower end portions of the mold body, respectively, which define an open ended upper cavity in the aperture thereof, having a cross sectional configuration in first planes transverse the axis of the mold body corresponding to the cross sectional configuration of the molten metal body to be cast therein, and an open ended lower cavity in the aperture of the mold body, having a cross sectional configuration in second planes transverse the axis of the mod body corresponding to the cross sectional configuration of the upper cavity, but greater in cross sectional area than that of the upper cavity in each of said second planes so that in the casting operation an annulus of open air is provided about the molten metal body as it emerges from the upper cavity and elongates along the axis of the mold body in the lower cavity,

the mold body having guide means which are angularly spaced about the axis thereof, and monolithically outstanding in the same material on the lower end portion of the mold body in the lower cavity of the aperture therein, to mate with the stool in the stage preliminary to the casting operation,

the mold body having a series of closely spaced holes in the inner peripheral portion thereof, which are generally symmetrically arrayed about the axis of the mold body to terminate at the inner periphery thereof and open into the lower cavity in the aperture of the mold body between the guide means and the upper cavity in the aperture of the mold body,

the mold body having an annular passage therein which extends about the axis of the mold body and opens into the series of holes, and

the mold body having a series of angularly spaced ports arrayed about the axis thereof, which are recessed in the mold body at the outer periphery thereof to interface with the liquid coolant discharge means during the casting operation, and which open into the annular passage in the mold body to discharge the liquid coolant into the annulus through the series of holes and direct cool the molten metal body when it has emerged from the upper cavity in the aperture of the mold body and is elongating along the axis thereof.

35. The annular mold according to claim 34 wherein the mold body has an annular surface extending about the outer periphery thereof which interfaces with the liquid coolant discharge means, and a circumferential groove in said outer peripheral surface which has a series of mullions therein that are angularly spaced about the groove and axially upstanding therein of the same material, to form the ports, the mullions being radially outwardly spaced from the bottom of the groove, to leave an annular channel about the axis of the mold body between the mullions and the bottom of the groove, which channel opens into the series of holes in the inner peripheral portion of the mold body.

36. The annular mold according to claim 35 wherein the groove is formed in the upper end portion of the mold body and the series of holes is sharply angled downwardly therefrom in the general direction of the axis of the mold body.

37. The annular mold according to claim 34 wherein the mold body has a first annular surface extending about the outer periphery thereof to interface with the liquid coolant discharge means, and second and third annular surfaces which extend about the axis of the mold body at the inner peripheries of the upper and lower end portions of the mold body, respectively, the second of which annular surfaces extends generally parallel to the axis of the mold body and defines the open ended upper cavity in the aperture thereof, and the third of which annular surfaces defines the open ended lower cavity in the aperture of the mold body, the cross sectional configuration of the lower cavity in said second planes of the mold body flaring relatively outwardly from the axis of the mold body in the direction relatively toward the lower end thereof from the upper end thereof, to form a progressively enlarged annulus of open air about the molten metal body as it emerges from the upper cavity and elongates along the axis of the mold body in the lower cavity, the guide means taking the form of a set of angularly spaced lugs which are monolithically outstanding on the third annular surface in the same material, to mate with the stool in the stage preliminary to the casting operation, and the series of ports being formed by a circumferential groove in the outer peripheral portion of the mold body at the first annular surface thereof, which has a series of mullions that are angularly spaced about the groove and monolithically axially upstanding therein of the same material, to form the ports.

38. The annular mold according to claim 37 wherein the mullions are radially outwardly spaced from the bottom of the groove, to leave an annular channel about the axis of the mold body between the mullions and the bottom of the groove.

39. The annular mold according to claim 37 wherein the groove is formed in the upper end portion of the mold body, and the series of holes is sharply angled downwardly therefrom in the general direction of the axis of the mold body.

40. The annular mold according to claim 37 wherein the first and second annular surfaces of the mold body are cylindrical, and the third annular surface thereof is comprised of an axially extending series of conical sections, the uppermost of which has the series of closely spaced holes opening therein, and the lowermost of which has the series of angularly spaced lugs monolithically outstanding thereon.

41. In an annular molten metal casting unit for insertion in an aperture in a metal casting table to form an open ended molten metal casting station thereon through which the molten metal to be cast is poured along a vertical axis of the table and cast into a molten metal body, and wherein during the casting procedure, the casting station has a stool operatively disposed therebelow on the axis of the table to telescopically engage with the bottom of the metal casting unit at a stage preliminary to the casting operation, and then in the operation itself, to provide a relatively reciprocable support for the molten metal body as it progressively emerges from the metal casting unit and elongates along the axis of the table, and wherein moreover, the metal casting unit has an opening formed therein about the molten metal body, and means formed thereabout on the table for discharging liquid coolant through the opening to direct cool the molten metal body as it emerges from the metal casting unit and elongates along the axis of the table,

an annular mold which is formed as a monolithic body of mold forming material having a vertical axis, upper and lower ends, an aperture between the ends thereof on the mold body axis, and an annular flange which is relatively outturned about the mold body axis, and monolithically outstanding in the same material at the outer periphery of the mold body, to abut the table and receive support therefrom when the metal casting unit is inserted in the aperture of the table coaxially thereof, to form the station,

the mold body having annular surfaces extending about the axis thereof at the inner peripheries of the upper and lower end portions of the mold body, respectively, which define an open ended upper cavity in the aperture thereof, having a cross sectional configuration in first planes transverse the axis of the mold body corresponding to the cross sectional configuration of the molten metal body to be cast therein, and an open ended lower cavity in the aperture of the mold body, having a cross sectional configuration in second planes transverse the axis of the mold body corresponding to the cross sectional configuration of the upper cavity, but greater in cross sectional area than that of the upper cavity in each of said second planes so that in the casting operation an annulus of open air is provided about the molten metal body as it emerges from the upper cavity and elongates along the axis of the mold body in the lower cavity,

the mold body having guide means which are angularly spaced about the axis thereof, and monolithically outstanding in the same material on the lower end portion of the mold body in the lower cavity of the aperture therein, to mate with the stool in the stage preliminary to the casting operation,

the mold body having a series of closely spaced holes in the inner peripheral portion thereof, which are generally symmetrically arrayed about the axis of the mold body to terminate at the inner periphery thereof and open into the lower cavity in the aperture of the mold body between the guide means and the upper cavity in the aperture of the mold body,

the mold body having an annular passage therein which extends about the axis of the mold body and opens into the series of holes,

the mold body having a series of angularly spaced ports arrayed about the axis thereof, which are recessed in the mold body at the outer periphery thereof to interface with the liquid coolant discharge means during the casting operation, and which open into the annular passage in the mold body to discharge the liquid coolant into the annulus through the series of holes and direct cool the molten metal body when it has emerged from the upper cavity in the aperture of the mold body and is elongating along the axis thereof, and

an annular baffle which is sleeved about the series of ports in the mold body and has a series of holes symmetrically arrayed thereabout to meter the coolant flow into the ports from the liquid coolant discharge means.

42. The annular molten metal casting unit according to claim 41 wherein the mold body has a first annular surface extending about the outer periphery thereof to interface with the liquid coolant discharge means, and second and third annular surfaces which extend about the axis of the mold body at the inner peripheries of the upper and lower end portions of the mold body, respectively, the second of which annular surfaces extends generally parallel to the axis of the mold body and defines the open ended upper cavity in the aperture thereof, and the third of which annular surfaces defines the open ended lower cavity in the aperture of the mold body, the cross sectional configuration of the lower cavity in said second planes of the mold body flaring relatively outwardly from the axis of the mold body in the direction relatively toward the lower end thereof from the upper end thereof, to form a progressively enlarged annulus of open air about the molten metal body as it emerges from the upper cavity and elongates along the axis of the mold body in the lower cavity, the guide means taking the form of a set of angularly spaced lugs which are monolithically outstanding on the third annular surface in the same material, to mate with the stool in the stage preliminary to the casting operation, and the series of ports being formed by a circumferential groove in the outer peripheral portion of the mold body at the first annular surface thereof, which has a series of mullions that are angularly spaced about the groove and monolithically axially upstanding therein of the same material, to form the ports, the mold body having an annular rabbet about the groove, at the outer peripheral edges thereof, and the annular baffle being seated in the rabbet.

43. In an annular molten metal casting unit for insertion in an aperture in a metal casting table to form an open ended molten metal casting station thereon through which the molten metal to be cast is poured along a vertical axis of the table and cast into a molten metal body, and wherein during the casting procedure, the casting station has a stool operatively disposed therebelow on the axis of the table to telescopically engage with the bottom of the metal casting unit at a stage preliminary to the casting operation, and then in the operation itself, to provide a relatively reciprocable support for the molten metal body as it progressively emerges from the metal casting unit and elongates along the axis of the table, and wherein moreover, the metal casting unit has an opening formed therein about the molten metal body, and means formed thereabout on the table for discharging liquid coolant through the opening to direct cool the molten metal body as it emerges from the metal casting unit and elongates along the axis of the table,

an annular mold which is formed as a monolithic body of mold forming material having a vertical axis, upper and lower ends, an aperture between the ends thereof on the mold body axis, and an annular flange which is relatively outturned about the mold body axis, and monolithically outstanding in the same material at the outer periphery of the mold body, to abut the table and receive support therefrom when the metal casting unit is inserted in the aperture of the table coaxially thereof, to form the station,

the mold body having angularly spaced guide means about the axis thereof, which are monolithically outstanding in the same material on the lower end portion of the mold body in the aperture thereof, to mate with the stool in the stage preliminary to the casting operation,

angularly spaced ports about the axis thereof which are recessed in the outer periphery of the mold body to interface with the liquid coolant discharge means, and to open into the aperture of the mold body between the guide means and the upper end portion of the mold body during the casting operation, so that the liquid coolant can discharge through the ports to direct cool the molten metal body as it emerges from the upper end portion of the mold body and elongates along the axis thereof,

a pair of first and second additional openings in the upper and lower end portions of the mold body, respectively, and

a fluid flow passage in the mold body, which is interconnected between the first and second additional openings to transmit fluid from one additional opening to the other for discharge from the mold body, relatively outside thereof,

44. The annular molten metal casting unit according to claim 43 wherein the ports are defined by outer peripheral portions of the mold body which monolithically upstand in the same material between the upper and lower end portions of the mold body, generally axially thereof, and the fluid flow passage extends through one of the port defining outer peripheral portions of the mold body, axially thereof.

45. The annular molten metal casting unit according to claim 43 wherein the mold body has an annular rabbet about the inner periphery thereof at the upper end thereof, the first additional opening is formed in the axially extending wall of the rabbet, and the unit further comprises a ring of graphite or the like which is seated in the rabbet so that fluid transmitted in the passage to the first additional opening from the second additional opening, can be forced through the ring in the direction of the axis of the mold body, to form an annulus of fluid about the molten metal body as it is cast within the aperture of the mold body.

46. The annular molten metal casting unit according to claim 43 wherein the flange is monolithically outstanding in the same material on the lower end portion of the mold body at the outer periphery thereof, the mold body has an annular rabbet about the outer periphery thereof at the upper end thereof, to form a pair of annular shoulders about the rabbet and the upper end of the mold body, with which to form a pair of annular liquid coolant seals about the axis of the mold body when the metal casting unit is inserted in the aperture of the table, which seals are relatively radially spaced apart from one another about the axis of the mold body, and the first additional opening is disposed on the step of the rabbet between the pair of seals, to intercept liquid coolant which leaks across the relatively radially outer seal, and discharge the same in the direction of the second additional opening, before the leakage can penetrate the relatively radially inner seal.

47. In a molten metal casting apparatus having a pair of fluid flow openings therein and a fluid flow passage therebetween which is connected with the pair of openings to deliver liquid to one opening from the other,

a device for detecting liquid flow in the passage comprising:

a liquid receptacle which is in communication with the passage, to receive a portion of the liquid flow therein, and has indicator means thereon including a transparent window which is exposed relatively outside of the apparatus for viewing by an operator thereof, so that the portion of liquid flow in the receptacle is made visually apparent to the operator through the window of the receptacle.

48. The molten metal casting apparatus according to claim 47 wherein the indicator means also include means of changeable color which are interactive with the portion of liquid flow to change color in the window of the receptacle.

49. The molten metal casting apparatus according to claim 47 wherein the receptacle has an axis, a bore of predetermined diameter with opposing ends which are disposed on the axis of the receptacle, and relatively proximal to and remote from the passage, respectively, and a relatively reduced diameter throat which is disposed in the relatively remote end of the bore transverse the axis of the receptacle and opens onto the window of the receptacle, and wherein the proximal end of the bore is connected with the passage to receive the portion of liquid flow therein, and the indicator means also include signaling means which are disposed in the bore and responsive to the presence of the portion of liquid flow therein, to pass through the throat and appear at the window of the receptacle.

50. The molten metal casting apparatus according to claim 49 wherein the signaling means include means of changeable color which are interactive with the portion of liquid flow, to pass through the throat and appear at the window of the receptacle with the flow.

51. The molten metal casting apparatus according to claim 49 wherein the receptacle has a portion thereof which projects relatively outside of the apparatus on the axis of the receptacle, with the window therein for viewing by the operator of the apparatus, and the relatively projecting portion of the receptacle has a cavity therein on the opposite side of the throat from the bore to receive the signaling means when the same pass through the throat.

52. The molten metal casting apparatus according to claim 49 wherein the receptacle has an end thereof which is exposed to the outside of the apparatus for viewing by the operator thereof, with the window therein, on the axis of the receptacle, the throat opens to atmosphere at the window of the receptacle, and the signaling means include a signaling device which is responsive to the presence of the portion of the liquid flow in the bore to project through the throat relatively outside the end of the receptacle at the window, for viewing by the operator.