This invention patent application addresses a thermal launder that allows the transport of white metal (WM) or other molten material to a converter or furnace or from these to a transfer pot while keeping it molten, with a viscosity that allows the material to continue flowing en route.

An apparatus and method is disclosed for forming an item in a mould using a casting process, typically a counter gravity casting system. Heating assembly, transfer assembly and mould filling assembly can be used in combination. The transfer assembly includes apparatus and method for removing sedimentation from the liquid metal and/or metal alloy received from the heating assembly and extracting the same prior to the metal and/or metal alloy reaching the mould filling assembly at which the same is supplied to fill a cavity of a mould and which, once filled, can be slid to a location to cool and thereby make available the mould filling assembly for the next mould to be filled. This apparatus and method provide an efficient, high throughput system, along with high quality cast items.

An apparatus and method is disclosed for forming an item in a mould using a casting process, typically a counter gravity casting system. Heating assembly, transfer assembly and mould filling assembly can be used in combination. The transfer assembly includes apparatus and method for removing sedimentation from the liquid metal and/or metal alloy received from the heating assembly and extracting the same prior to the metal and/or metal alloy reaching the mould filling assembly at which the same is supplied to fill a cavity of a mould and which, once filled, can be slid to a location to cool and thereby make available the mould filling assembly for the next mould to be filled. This apparatus and method provide an efficient, high throughput system, along with high quality cast items.

A deposition system for casting an object additively by producing multiple production layers having mold regions and object regions defined by the mold regions includes a deposition unit, a first induction heating unit, and an induction heating power supply unit. The deposition unit deposits molten metal in a working area of the object region of the currently-produced production layer according to a building plan defining a deposition path and a deposition velocity. The first induction heating unit heats the working area and is held at a working distance above a height of a current one of the mold regions. The induction heating power supply unit is coupled to the first induction heating unit and provides current at a desired magnitude and frequency. The first induction heating unit generates from the current a magnetic field which extends to the working area.

A deposition system for casting an object additively by producing multiple production layers having mold regions and object regions defined by the mold regions includes a deposition unit, a first induction heating unit, and an induction heating power supply unit. The deposition unit deposits molten metal in a working area of the object region of the currently-produced production layer according to a building plan defining a deposition path and a deposition velocity. The first induction heating unit heats the working area and is held at a working distance above a height of a current one of the mold regions. The induction heating power supply unit is coupled to the first induction heating unit and provides current at a desired magnitude and frequency. The first induction heating unit generates from the current a magnetic field which extends to the working area.

A casting system for producing an object with multiple layers having mold regions and object regions includes a mold construction unit, at least one deposition system, and a controller. The mold construction unit constructs the mold regions of the currently-produced layer. The deposition system includes a movable deposition unit, a first induction heating unit, and an induction heating power supply unit. The movable deposition unit deposits molten metal in a working area along a deposition path and with a deposition velocity. The first induction heating unit heats the working area from a working distance above a height of a current mold region. The power supply unit provides current to generate therefrom a magnetic field extending to the working area. The controller controls the system such that the magnetic field heats a desired zone in the working area to a target temperature.

A casting system for producing an object with multiple layers having mold regions and object regions includes a mold construction unit, at least one deposition system, and a controller. The mold construction unit constructs the mold regions of the currently-produced layer. The deposition system includes a movable deposition unit, a first induction heating unit, and an induction heating power supply unit. The movable deposition unit deposits molten metal in a working area along a deposition path and with a deposition velocity. The first induction heating unit heats the working area from a working distance above a height of a current mold region. The power supply unit provides current to generate therefrom a magnetic field extending to the working area. The controller controls the system such that the magnetic field heats a desired zone in the working area to a target temperature.

A system for melting metals for casting includes one or more arc welding power supplies configured to provide one or more arc welding outputs, and one or more electrodes operatively connected to the one or more arc welding outputs. A solid metal holder is configured to hold a solid metal to be melted by one or more arcs formed between the one or more electrodes and the solid metal to generate a molten metal. A container is positioned proximate the solid metal holder to receive the molten metal. A robot is proximate both the container and a mold and/or a die cast machine. The robot has an arm configured to manipulate the container containing the molten metal and pour the molten metal from the container into the mold and/or the die cast machine for casting.

A system for melting metals for casting includes one or more arc welding power supplies configured to provide one or more arc welding outputs, and one or more electrodes operatively connected to the one or more arc welding outputs. A solid metal holder is configured to hold a solid metal to be melted by one or more arcs formed between the one or more electrodes and the solid metal to generate a molten metal. A container is positioned proximate the solid metal holder to receive the molten metal. A robot is proximate both the container and a mold and/or a die cast machine. The robot has an arm configured to manipulate the container containing the molten metal and pour the molten metal from the container into the mold and/or the die cast machine for casting.

An apparatus for moulding battery components including a molten metal feed trough, a mould block adjacent to the feed trough, a weir between the feed trough and each cavity and a supply for feeding molten metal to the feed trough. The mould block has at least one mould cavity and a cooling arrangement which cools the mould block, and the mould block is provided with a heating arrangement adjacent to the or each mould cavity. In use, the heating arrangement maintains at least part of the, or each, mould cavity at an elevated temperature relative to the average operational temperature of the mould block.