Matrix Riser Breaker Insert
AssigneePorvair PLC
InventorsDonald B. Craig, Christopher J. Mann, David P. Haack, James R. Schmahl
Life of this patent
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Abstract
A casting system for molding metal. The casting system has a mold comprising a cavity in a predefined shape. A riser in flow communication with the mold wherein the riser provides molten metal to said cavity as the molten metal freezes. A riser breaker insert is between the mold and the riser wherein the riser breaker insert comprises voids. A molten metal supply is provided which is capable of filling the mold and the voids of said riser breaker insert and at least partially filling the riser.
Claims52
A casting system for molding metal comprising:
- a mold comprising a cavity in a predefined shape;
- a riser in flow communication with said mold wherein said riser provides molten metal to said cavity as said molten metal freezes;
- a riser breaker insert between said mold and said riser wherein said riser breaker insert comprises voids;
- a molten metal supply capable of filling said mold and said voids of said riser breaker insert and at least partially filling said riser.
A ceramic riser breaker insert comprising:
- a matrix of solid ceramic filaments forming a gross shape with an inner boundary, an outer boundary and a bulk density of at least 10 vol % to no more than 50 vol % between said inner boundary and said outer boundary.
A method for casting metal comprising:
- positioning a mold comprising a cavity;
- attaching a riser in flow communication with said mold;
- inserting a riser breaker insert between said mold and said riser wherein said riser breaker insert comprises voids;
- charging said mold with an excess of molten metal wherein said molten metal fills said mold, at least partially fills said riser and at least partially fills said voids in said riser breaker insert;
- cooling said molten metal in said mold wherein upon said cooling said molten metal contracts;
- allowing molten metal to pass from said riser through said voids of said riser breaker insert to maintain a full mold as said molten metal contracts thereby forming a blank comprising a cast, waste and said riser breaker in said blank between said cast and said waste;
- and
- separating said cast from said waste at said riser breaker insert.
A method of forming a ceramic riser breaker insert comprising:
- forming a ceramic precursor;
- extruding said ceramic precursor into filaments to form an inner boundary, an outer boundary, top filaments spanning between said inner boundary and said outer boundary and bottom filaments spanning between said inner boundary and said outer boundary thereby forming a green riser breaker insert;
- heating said green riser breaker insert to sinter said ceramic precursor thereby forming said ceramic riser breaker insert.
Dependencies are inferred from the claim text.