A smart molten metal pump system and method automatically controls the operating speed of the pump rather than requiring an operator to control the speed. The system includes a pump, a controller for controlling the speed of the pump, and one or more of a temperature sensor (such as a thermocouple), one or more of a device (such as a laser or float) to measure the depth of the molten metal, and one or more of a vibration sensor (such as an accelerometer) to measure vibration. The controller receives input about the temperature of the molten metal, and/or about the depth of the molten metal, and/or about the vibration of the pump or one or more pump components, and possibly other data. The controller analyzes the one or more inputs to vary the speed of the pump, turn the pump off, and/or send a communication to an operator.

A launder for use in moving molten metal includes at least one relatively narrow channel through which molten metal flows. Using a narrow, rather than broad, channel permits better control of the flow and helps prevent overflowing the launder or a structure adjacent the launder. A molten metal pumping or transfer system may utilize a launder as disclosed herein.

A system according to aspects of the invention includes a pump and a refractory casing that houses the pump or is in fluid communication with the pump. As the pump operates it moves molten metal upward through an uptake section of the casing until it reaches a rectangular outlet wherein it exits the vessel. The rectangular outlet is configured to be connected to, or may be attached to, a launder. Another system uses a wall to divide a cavity of the chamber into two portions. The wall has an opening and a pump pumps molten metal from a first portion into a second portion until the level in the second portion reaches an outlet and exits the vessel.

A scrap melting system and method includes a vessel that is configured to retain molten metal and a raised surface about the level of molten metal in the vessel. Solid metal is placed on the raised surface and molten metal from the vessel is moved upward from the vessel and across the raised surface to melt at least some of the solid metal. The molten metal is preferably raised from the vessel to the raised surface by a molten metal pumping device or system. The molten metal moves from the raised surface and into a vessel or launder.

A scrap melting system and method includes a vessel that is configured to retain molten metal and a raised surface about the level of molten metal in the vessel. Solid metal is placed on the raised surface and molten metal from the vessel is moved upward from the vessel and across the raised surface to melt at least some of the solid metal. The molten metal is preferably raised from the vessel to the raised surface by a molten metal pumping device or system. The molten metal moves from the raised surface and into a vessel or launder.

A production method for a component having integrated channels for internal fluid guidance, having a first region, which is connected to a second region, and wherein the channels extend both through the first region and through the second region. The geometry of the component is modified to the technological characteristics of both production methods. The first region is produced by a method for casting using lost models without undercuts, and proceeding from the first region, the second region is built up using an additive manufacturing method.

A lead delivery apparatus for a cast on strap machine is arranged to deliver a predetermined volume of molten lead to a mould. The apparatus includes a first needle valve, a second needle valve, and a housing. The housing includes a reservoir having an inlet and an outlet. The reservoir inlet is in fluid communication with a molten lead supply. The reservoir is supplied with molten lead during use such that the molten lead in the reservoir is maintained at a constant height. A volume block has an inlet, an outlet and a through cavity and the volume block inlet is in fluid communication with the reservoir outlet. The through cavity together with the second needle valve defines the predetermined volume of molten lead received from the reservoir.

A lead delivery apparatus for a cast on strap machine is arranged to deliver a predetermined volume of molten lead to a mould. The apparatus includes a first needle valve, a second needle valve, and a housing. The housing includes a reservoir having an inlet and an outlet. The reservoir inlet is in fluid communication with a molten lead supply. The reservoir is supplied with molten lead during use such that the molten lead in the reservoir is maintained at a constant height. A volume block has an inlet, an outlet and a through cavity and the volume block inlet is in fluid communication with the reservoir outlet. The through cavity together with the second needle valve defines the predetermined volume of molten lead received from the reservoir.

A foundry casting system and process employs an inert gas delivery and recovery system for casting parts which results in cast parts having improved metalurgical characteristics. The system may be employed in sand, die casting, semi-permanent and permanent casting environments. Pressurized inert gas may be diffused into the mold before, during and after the metal pouring step. The resulting casting is free from oxides and dissolved hydrogen gas as they are removed from the mold cavity. This results in higher quality castings as well as increased production output due to faster cooling cycles.

A foundry casting system and process employs an inert gas delivery and recovery system for casting parts which results in cast parts having improved metalurgical characteristics. The system may be employed in sand, die casting, semi-permanent and permanent casting environments. Pressurized inert gas may be diffused into the mold before, during and after the metal pouring step. The resulting casting is free from oxides and dissolved hydrogen gas as they are removed from the mold cavity. This results in higher quality castings as well as increased production output due to faster cooling cycles.