A method of producing a steel foam component includes providing a mold defining a cavity. The method also includes positioning an insert within the cavity of the mold. The insert can be configured to form a generally uniform pattern of pores within the steel foam component, and in some cases occupies at least 20% of the cavity. The method can further include pouring molten steel into the cavity, cooling the molten steel into the steel foam component, and removing the steel foam component and the insert from the mold. Steel components having internal shapes corresponding to the insert(s) are also provided.

A number of variations may include at least one mold portion that may define a first cavity, a circular gating system, and at least one sprue. The circular gating system may surround the first cavity and define a continuous in-gate from the circular gating to the first cavity. The at least one sprue and at least one vent may be in fluid communication with the circular gating system and the first cavity.

A number of variations may include at least one mold portion that may define a first cavity, a circular gating system, and at least one sprue. The circular gating system may surround the first cavity and define a continuous in-gate from the circular gating to the first cavity. The at least one sprue and at least one vent may be in fluid communication with the circular gating system and the first cavity.

An apparatus and method for filtering molten metal, such as aluminum or an aluminum alloy includes at least one ceramic foam filter or any other type of filtration media such as porous tube or alumina balls disposed in a receptacle for the molten metal. A vibrator vibrates at least one of the filter, the receptacle or the metal and may be used to induce priming, filtering and/or drainage of the filter. The vibrator may be retrofitted to an existing filter system and may be adjustable in frequency and amplitude. The vibration may be continuous over a given period or produced in a single shock.

An apparatus and method for filtering molten metal, such as aluminum or an aluminum alloy includes at least one ceramic foam filter or any other type of filtration media such as porous tube or alumina balls disposed in a receptacle for the molten metal. A vibrator vibrates at least one of the filter, the receptacle or the metal and may be used to induce priming, filtering and/or drainage of the filter. The vibrator may be retrofitted to an existing filter system and may be adjustable in frequency and amplitude. The vibration may be continuous over a given period or produced in a single shock.

A decorative emblem comprises a plurality of unit emblem bodies; a plurality of fastening legs connected correspondingly to the plurality of unit emblem bodies and having a reduced diameter portion formed on the center thereof in such a manner as to be easily bent and broken; and leg fixing bars adapted to fix the ends of the fastening legs thereto.

The subject of the invention is a process for the production of at least partly thin-walled and aluminium castings with sand moulding technology by gravity casting, which allows producing casts with 100 times or favourably 200-400 times larger overall dimensions in case of 1-3 mm wall thickness. The main idea of the process is that sand mould containing mould cavity is provided, melt of aluminium content is produced, the melt is introduced into the mould cavity at several points through a gating system of narrowing cross section. A further subject of the invention is a sand mould fitted with a gating system to produce at least partly thin-walled castings with sand moulding technology, by gravity casting. The wall thickness of thin-walled segments is 1-3 mm and the largest dimension is more than a 100 but favourably at least 200-400 multiple of the wall thickness. The main idea behind the sand mould with a gating system is that it contains a mould cavity allowing the production of at least partly thin-walled castings, and is equipped with a gating system, which is composed of at least two sprues and one ingate to each having a porthole into the mould cavity and in liquid contact with the sprues.

A casting mold includes a cover member covering the inner wall of a bent portion (a first bent portion, etc.) of a passageway. The cover member has a bottomed cylindrical shape having an axis extending in an up-down direction, and includes an upper hole, lateral holes, and at least one flange (a side wall flange). At least one of a fixed mold and a movable mold includes a flange housing groove in a separation surface. When the cover member is disposed in the bent portion and the casting mold is closed, the flange is housed in the flange housing groove, and the cover member is held in a state where a gap is formed between the inner wall of the bent portion and the outer wall of the cover member.

A casting mold includes a cover member covering the inner wall of a bent portion (a first bent portion, etc.) of a passageway. The cover member has a bottomed cylindrical shape having an axis extending in an up-down direction, and includes an upper hole, lateral holes, and at least one flange (a side wall flange). At least one of a fixed mold and a movable mold includes a flange housing groove in a separation surface. When the cover member is disposed in the bent portion and the casting mold is closed, the flange is housed in the flange housing groove, and the cover member is held in a state where a gap is formed between the inner wall of the bent portion and the outer wall of the cover member.

An improved filtration system is provided. The filtration system comprises a pour cup comprising a reservoir and a filter engagement region wherein the filter engagement region comprises a pour cup taper, tab slots and a bottom. The filtration system also comprises a filter wherein the filter comprises a filter taper and filter tabs wherein the filter tabs can be received by the tab slots in one rotational orientation of the filter relative to the pour cup and the tab slots engage with the bottom in a second rotational orientation of the filter relative to the pour cup.