# US 8,540,010 B2 · Sequential mold filling

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- Number: US 8,540,010 B2
- Document ID: US8540010B2
- Status: Granted
- Kind: B2
- Application number: 11/787,431
- Filed: 2007-04-16
- Published: 2008-01-17
- Granted: 2013-09-24
- Earliest claimed: 2006-04-19
- Assignees: Howmet Corporation
- Applicants: Brian D. Przeslawski; Rajeev V. Naik
- Inventors: Brian D. Przeslawski; Rajeev V. Naik
- Web page: https://patentgrep.com/patent/US8540010B2

## CPC

- B22C 9/04: Use of lost patterns
- B22C 9/08: Features with respect to supply of molten metal, e.g. ingates, circular gates, skim gates
- C30B 11/002: {Crucibles or containers for supporting the melt}
- C30B 29/52: Alloys
- Y10T 428/12229: Intermediate article [e.g., blank, etc.]
- B22C: FOUNDRY MOULDING (moulding refractory materials in general B28B)
- C30B: SINGLE-CRYSTAL GROWTH (by using ultra-high pressure, e.g. for the formation of diamonds, B01J3/06); UNIDIRECTIONAL SOLIDIFICATION OF EUTECTIC MATERIAL OR UNIDIRECTIONAL DEMIXING OF EUTECTOID MATERIAL; REFINING BY ZONE-MELTING OF MATERIAL (zone-refining of metals or alloys C22B); PRODUCTION OF A HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE (casting of metals, casting of other substances by the same processes or devices B22D; working of plastics B29; modifying the physical structure of metals or alloys C21D, C22F); SINGLE CRYSTALS OR HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; AFTER-TREATMENT OF SINGLE CRYSTALS OR A HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE (for producing semiconductor devices or parts thereof H10); APPARATUS THEREFOR
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

Method and apparatus for casting molten metal or alloy into a plurality of molds that are connected by mold ingate passages in melt flow communication to a melt supply passage which is configured in a manner to completely or partially fill the molds with the molten metal or alloy sequentially one after another. Filling of the molds in this manner provides uniform mold filling, reduces foreign matter in molds filled after the first-filled mold, and improves quality of the cast articles.

## Claims

### Claim 1

Method for casting molten metal or alloy, comprising providing metal or alloy melt in a melt-containing mold cup of a mold assembly and supplying the melt from the mold cup to a first melt supply passage of the mold assembly to which a first plurality of molds are connected in melt flow communication in series arrangement one after another and supplying the melt from the first melt supply passage via a melt supply connector passage to a second supply passage to which a second plurality of molds are connected in melt flow communication in series arrangement one after another such that the first plurality of molds are at least partially filled before the second plurality of molds.

### Claim 2 (depends on 1)

The method of claim 1 including connecting the first melt supply passage in melt flow communication to the second melt supply passage by said connector passage configured in a manner that the first plurality of molds are completely filled before the second plurality of molds.

### Claim 3 (depends on 1)

The method of claim 1 wherein the connector passage is configured to have an arc shape.

### Claim 4 (depends on 1)

The method of claim 1 including configuring the molds to cast equiaxed polycrystalline grain solidified articles.

### Claim 5 (depends on 1)

The method of claim 1 including configuring the molds to cast directionally solidified articles therein having a plurality of columnar grains along an axis of the mold.

### Claim 6 (depends on 1)

The method of claim 1 including configuring the molds to cast single crystal articles therein having a single grain.

### Claim 7

Method for casting molten metal or alloy, comprising providing metal or alloy melt in a melt-containing mold cup of a mold assembly and supplying the melt from the mold cup to a plurality of molds that are connected in melt flow communication at different elevations in series arrangement one after another with the molten metal or alloy being supplied to the bottom of each mold in the series by a melt supply passage extending from the top of the preceding mold in the series.

### Claim 8

Mold assembly for casting molten metal or alloy melt, comprising a melt-containing mold cup, a melt supply passage in melt flow communication to the mold cup, and a plurality of molds that are connected in melt flow communication to the melt supply passage in series arrangement one after another wherein adjacent molds of the series are connected in melt flow communication by a respective melt supply passage extending from a top region of a preceding mold to a bottom region of a next succeeding mold to provide top-to-bottom molten metal flow relation between adjacent molds, and wherein the respective melt supply passage is configured in a manner that each of the molds of the series is at least partially filled before the next mold in the series is at least partially filled.