An exemplary casting assembly for an engine block includes, among other things, an insert and at least one magnet configured to retain the insert in a predefined position within an engine block mold cavity. An exemplary engine block casting method includes, among other things, positioning at least one insert in a mold cavity, retaining the insert in position with at least one magnet, introducing material into the mold cavity to form an engine block, and solidifying the material to secure the insert within the engine block.

An exemplary casting assembly for an engine block includes, among other things, an insert and at least one magnet configured to retain the insert in a predefined position within an engine block mold cavity. An exemplary engine block casting method includes, among other things, positioning at least one insert in a mold cavity, retaining the insert in position with at least one magnet, introducing material into the mold cavity to form an engine block, and solidifying the material to secure the insert within the engine block.

A liquid epoxy resin, a powdered metal and a hardening agent are provided as a filling material (S) and poured into an insert hole (82). The filling material (S) is in a liquid state under a normal temperature so as to make the filling material (S) handle easily in the filling work. The filling material (S) is hardened at a clearance between a bushing tool (12) and the insert hole (82). The filling material (S) is placed between the bushing tool (12) and the insert hole (82) to enhance a heat-conductivity therebetween. By heat treating a metallic mold die 80, it is possible to char the epoxy resin. This makes it possible to deposit the powdered metal (copper or the like) over an entire area of the clearance so as to highly enhance the heat-conductivity.

A liquid epoxy resin, a powdered metal and a hardening agent are provided as a filling material (S) and poured into an insert hole (82). The filling material (S) is in a liquid state under a normal temperature so as to make the filling material (S) handle easily in the filling work. The filling material (S) is hardened at a clearance between a bushing tool (12) and the insert hole (82). The filling material (S) is placed between the bushing tool (12) and the insert hole (82) to enhance a heat-conductivity therebetween. By heat treating a metallic mold die 80, it is possible to char the epoxy resin. This makes it possible to deposit the powdered metal (copper or the like) over an entire area of the clearance so as to highly enhance the heat-conductivity.

Techniques are disclosed for reducing macrosegregation in cast metals. Techniques include providing an eductor nozzle capable of increasing mixing in the fluid region of an ingot being cast. Techniques also include providing a non-contacting flow control device to mix and/or apply pressure to the molten metal that is being introduced to the mold cavity. The non-contacting flow control device can be permanent magnet or electromagnet based. Techniques additionally can include actively cooling and mixing the molten metal before introducing the molten metal to the mold cavity.

Disclosed is a transfer pump having a pump base with a pump chamber, tangential discharge and an outlet in the top surface of the pump base. A riser tube extends from the outlet and terminates at a launder in order to move molten metal out of a vessel with relatively little turbulence.

Disclosed is a transfer pump having a pump base with a pump chamber, tangential discharge and an outlet in the top surface of the pump base. A riser tube extends from the outlet and terminates at a launder in order to move molten metal out of a vessel with relatively little turbulence.

A casting furnace for manufacture of metal and/or ceramic components at high production rate is disclosed. The casting furnace comprises a melting chamber, a dual zone mold heating chamber and a dual zone mold cooling chamber. The melting chamber provides a source of molten alloy or ceramics with adequate superheat. The dual zone mold heating chamber includes an independently controlled primary heating zone and the secondary heating zone. The primary heating zone raises the mold temperature adequately to impart high gradient solidification conditions. The secondary heating zone assists the primary heating zone to minimize overheating of the majority of the mold. The dual zone mold cooling chamber comprises a primary cooling chamber and a secondary cooling chamber. The primary cooling chamber speeds up solidification in order to prevent defect formation and refine microstructure. The secondary cooling chamber slows down the cooling of castings to reduce residual stresses build up and minimize elemental segregation through augmenting solid-state diffusion of lower melting elements.

A casting furnace for manufacture of metal and/or ceramic components at high production rate is disclosed. The casting furnace comprises a melting chamber, a dual zone mold heating chamber and a dual zone mold cooling chamber. The melting chamber provides a source of molten alloy or ceramics with adequate superheat. The dual zone mold heating chamber includes an independently controlled primary heating zone and the secondary heating zone. The primary heating zone raises the mold temperature adequately to impart high gradient solidification conditions. The secondary heating zone assists the primary heating zone to minimize overheating of the majority of the mold. The dual zone mold cooling chamber comprises a primary cooling chamber and a secondary cooling chamber. The primary cooling chamber speeds up solidification in order to prevent defect formation and refine microstructure. The secondary cooling chamber slows down the cooling of castings to reduce residual stresses build up and minimize elemental segregation through augmenting solid-state diffusion of lower melting elements.

A pump having a motor, a pump base with a pump chamber, a tangential discharge and an outlet in the pump base. A riser tube extends upward from the outlet and terminates at or above a launder in order to move molten metal out of a vessel with relatively little turbulence.