Subsurface chills to improve railcar knuckle formation

  • US 9,308,578 B2
  • Filed: 12/21/2011
  • Issued: 04/12/2016
  • Est. Priority Date: 12/21/2011
  • Status: Active Grant
First Claim
Patent Images

1. An assembly for casting a light steel railcar coupler knuckle, comprising:

  • a cope mold portion, the cope portion having internal walls defining at least in part perimeter boundaries of a coupler knuckle mold cavity including a front face portion, a nose portion, a pulling face portion, a heel portion, a throat portion, a tail portion, a lock shelf portion, and a locking face portion;

    a drag mold portion, the drag mold portion having internal walls defining at least in part perimeter boundaries of a coupler knuckle mold cavity including a front face portion, a nose portion, a pulling face portion, a heel portion, a throat portion, a tail portion, a lock shelf portion, and a locking face portion;

    at least one riser preceding and engaged with at least one ingate in the front face portion;

    at least one internal core placed to define within the coupler knuckle a finger cavity, a pivot pin cavity forming a C-10 pin hole, and a kidney cavity;

    a first subsurface external chill positioned within the cope mold portion, the first chill positioned between the front face portion and the tail portion of the cope and drag mold portions and adjacent to the throat portion and the C-10 pin hole, the first chill offset at least ⅛



    from and adjacent the internal walls of the pulling face and the throat of the cope mold portion, where a wall of sand exists between the first chill and the internal walls of the coupler knuckle mold cavity;

    a second subsurface external chill positioned within the drag mold portion, the second chill positioned between the front face portion and the tail portion of the cope and drag mold portions and adjacent to the throat portion and the C-10 pin hole, the second chill offset at least ⅛



    from and adjacent the internal walls of the pulling face and the throat of the drag mold portion, where a wall of sand exists between the first chill and the internal walls of the coupler knuckle mold cavity;

    wherein the first and second chills are positioned within each of the cope and drag mold portions such that the chills contact each other along a centerline of the casting after the cope and drag mold portions are closed prior to casting;

    wherein a coupler knuckle is formable of metal from the cope and drag mold portions that include the chills, the coupler knuckle including an improved surface with reduced subsurface micro-shrinkage at a location of at least the throat of the coupler knuckle as compared to an equivalent surface cast in a process using a surface chill; and

    wherein the improved surface extends substantially between the pulling face and lock shelf of the coupler knuckle.

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