The invention relates to systems for transferring molten metal from one structure to another. Aspects of the invention include a transfer chamber constructed inside of or next to a vessel used to retain molten metal. The transfer chamber is in fluid communication with the vessel so molten metal from the vessel can enter the transfer chamber. A powered device, which may be inside of the transfer chamber, moves molten metal upward and out of the transfer chamber and preferably into a structure outside of the vessel, such as another vessel or a launder.

The invention relates to systems for transferring molten metal from one structure to another. Aspects of the invention include a transfer chamber constructed inside of or next to a vessel used to retain molten metal. The transfer chamber is in fluid communication with the vessel so molten metal from the vessel can enter the transfer chamber. A powered device, which may be inside of the transfer chamber, moves molten metal upward and out of the transfer chamber and preferably into a structure outside of the vessel, such as another vessel or a launder.

A process for high integrity castings of metals and their alloys includes the steps of providing at least a sand mold at desired elevated temperatures, delivering a molten metal into the mold, and supplying a predetermined amount of coolant to contact the surfaces of the casting at desired rates, times, and durations to achieve an acceptable level of progressive solidification from the distal end of the casting towards the riser until the casting has reached desired temperatures.

A process for high integrity castings of metals and their alloys includes the steps of providing at least a sand mold at desired elevated temperatures, delivering a molten metal into the mold, and supplying a predetermined amount of coolant to contact the surfaces of the casting at desired rates, times, and durations to achieve an acceptable level of progressive solidification from the distal end of the casting towards the riser until the casting has reached desired temperatures.

The present disclosure provides a method for collecting parameters for casting solidification simulation and a gridded design method for a pouring and riser system, comprising calculating thermodynamic parameters of a superalloy; obtaining cooling curves of the superalloy with different thickness; measuring a linear expansion coefficient of the superalloy as a function of temperature; the design method comprising: simulating a solidification process with tubular features of different thickness, and determining a feeding distance of the features of different thickness; establishing a gridded pouring and riser system, dividing the casting into a plurality of modules according to the thickness, and dividing a cell inside each module, and ensuring that a size of the cell is less than the feeding distance with the thickness; simulating filling and solidification of castings and the gridded pouring and riser system, and analyzing simulation results of defects.

The present disclosure provides a method for collecting parameters for casting solidification simulation and a gridded design method for a pouring and riser system, comprising calculating thermodynamic parameters of a superalloy; obtaining cooling curves of the superalloy with different thickness; measuring a linear expansion coefficient of the superalloy as a function of temperature; the design method comprising: simulating a solidification process with tubular features of different thickness, and determining a feeding distance of the features of different thickness; establishing a gridded pouring and riser system, dividing the casting into a plurality of modules according to the thickness, and dividing a cell inside each module, and ensuring that a size of the cell is less than the feeding distance with the thickness; simulating filling and solidification of castings and the gridded pouring and riser system, and analyzing simulation results of defects.

The invention provides a casting equipment (1) for casting melt (15) into a cast product (80) comprising a supply reservoir (10) for supplying the melt (15), a distribution reservoir (20), a casting apparatus (25) having a melt inlet connected to the distribution reservoir (20) for producing the cast product (80), a supply conduit (30) fluidly connecting the supply reservoir (10) and the distribution reservoir (20), an electromagnetic pump (35) provided on the supply conduit (30) and operable to generate a force in the melt (15) in the supply conduit (30), a level sensor (40) for measuring a level of the melt (15) in the distribution reservoir (20) and/or in the supply reservoir (10), a controller operably connected to the pump (35) and the level sensor (40), wherein the supply conduit (30) is sealed or sealable from a pressure of the atmosphere, wherein the controller is configured to control an operation of the pump (35) based on a level signal from the level sensor (40), and wherein, at least during a steady-state casting operation, the casting equipment is configured such that the supply conduit (30) defines a flow path that has a point that is higher than a surface of the melt in the supply reservoir (10) and/or the distribution reservoir (20), and the pump (35) is operated such that the metal level in the distribution reservoir (20) is at a predefined level such as to control a pressure of the melt (15) in the melt inlet of the casting apparatus (25).

The invention provides a casting equipment (1) for casting melt (15) into a cast product (80) comprising a supply reservoir (10) for supplying the melt (15), a distribution reservoir (20), a casting apparatus (25) having a melt inlet connected to the distribution reservoir (20) for producing the cast product (80), a supply conduit (30) fluidly connecting the supply reservoir (10) and the distribution reservoir (20), an electromagnetic pump (35) provided on the supply conduit (30) and operable to generate a force in the melt (15) in the supply conduit (30), a level sensor (40) for measuring a level of the melt (15) in the distribution reservoir (20) and/or in the supply reservoir (10), a controller operably connected to the pump (35) and the level sensor (40), wherein the supply conduit (30) is sealed or sealable from a pressure of the atmosphere, wherein the controller is configured to control an operation of the pump (35) based on a level signal from the level sensor (40), and wherein, at least during a steady-state casting operation, the casting equipment is configured such that the supply conduit (30) defines a flow path that has a point that is higher than a surface of the melt in the supply reservoir (10) and/or the distribution reservoir (20), and the pump (35) is operated such that the metal level in the distribution reservoir (20) is at a predefined level such as to control a pressure of the melt (15) in the melt inlet of the casting apparatus (25).

According to a casting method, a molten metal is sustained at a sustain position between a casting and the next casting, and the molten metal flow is divided from one pouring gate (44) to a plurality of sprue runners (46 and 47) in the casting. The sprue runners (46 and 47) are branched by a V-shaped portion (45) in a V-shape, and the sustain position of the molten metal is set above (any one of P1, P2 and P4) the V-shaped portion (45). The V-shaped portion (45) is filled with the molten metal while a repeated casting is carried out.

According to a casting method, a molten metal is sustained at a sustain position between a casting and the next casting, and the molten metal flow is divided from one pouring gate (44) to a plurality of sprue runners (46 and 47) in the casting. The sprue runners (46 and 47) are branched by a V-shaped portion (45) in a V-shape, and the sustain position of the molten metal is set above (any one of P1, P2 and P4) the V-shaped portion (45). The V-shaped portion (45) is filled with the molten metal while a repeated casting is carried out.