Hearth and casting system

Patent metadata

Field	Value
Publication number	US-9539640-B2
Application number	US-201615173114-A
Country	US
Kind code	B2
Filing date	Jun 3, 2016
Priority date	Feb 5, 2013
Publication date	Jan 10, 2017
Grant date	Jan 10, 2017

Abstract

A casting system, apparatus, and method. The casting system can include an energy source and a hearth, which can have a tapered cavity. The tapered cavity can have a first end portion and a second end portion, and the tapered cavity can narrow between the first and second end portions. Further, the tapered cavity can have an inlet at the first end portion that defines an inlet capacity, and one or more outlets at the second end portion that define an outlet capacity. Where the cavity has a single outlet, the outlet capacity can be less than the inlet capacity. Where the cavity has multiple outlets, the combined outlet capacity can match the inlet capacity. Further, the cross-sectional area of the tapered cavity near the inlet can be similar to the cross-sectional area of the inlet.

First claim

The invention claimed is:

1. A casting system comprising:
a hearth comprising:
an inlet defining an inlet cross-sectional area;
a plurality of outlets, wherein each outlet defines an outlet cross-sectional area less than the inlet cross-sectional area; and
a cavity between the inlet and the plurality of outlets, wherein the cavity defines a cavity cross-sectional area that is continually reduced from the inlet to the outlets; and

a plurality of molds, wherein a mold is aligned with each outlet of the hearth.

2. The casting system of claim 1 , wherein the sum of the outlet cross-sectional areas substantially matches the inlet cross-sectional area.

3. The casting system of claim 1 , wherein the hearth comprises:
a first wall; and
a second wall, wherein the cavity is at least partially defined between the first wall and the second wall, and wherein the first wall is not parallel to the second wall.

4. The casting system of claim 3 , wherein the first wall is angularly oriented approximately 1 degree to approximately 10 degrees relative to the second wall.

5. The casting system of claim 3 , wherein the plurality of outlets comprises a first outlet and a second outlet, the first outlet extends through the first wall, and the second outlet extends through the second wall.

6. The casting system of claim 5 , wherein the first outlet defines a first outlet cross-sectional area, the second outlet defines a second outlet cross-sectional area, and the second outlet cross-sectional area substantially matches the first outlet cross-sectional area.

7. The casting system of claim 1 , wherein the cavity defines a longitudinal axis, and wherein the outlets are symmetrically arranged relative to the longitudinal axis.

8. The casting system of claim 1 , wherein the molds are open-bottomed molds.

9. The casting system of claim 1 , comprising an energy source, wherein the energy source is structured to energize material in the hearth, and wherein a portion of the material forms a solidified skull that at least partially defines the cavity in the hearth.

10. The casting system of claim 1 , wherein each outlet comprises a pour lip, and wherein each pour lip is aligned with a mold of the casting system.

11. The casting system of claim 1 , wherein the hearth comprises a fluid based cooling system.

12. The casting system of claim 1 , wherein the plurality of molds are arranged for parallel casting.

13. The casting system of claim 1 , wherein the inlet comprises an inlet low edge, wherein the outlet comprises an outlet low edge, and wherein the outlet low edge is higher than the inlet low edge.

14. A hearth for use with a casting system, the hearth comprising:
a cavity comprising:
a first end portion; and
a second end portion, wherein the cavity defines a cavity cross-sectional area that is continually reduced from the first end portion to the second end portion;

an inlet at the first end portion, wherein the inlet defines an inlet capacity; and
an outlet at the second end portion, wherein the outlet defines an outlet capacity.

15. The hearth of claim 14 comprising:
a first wall; and
a second wall, wherein the cavity is defined between the first wall and the second wall, and wherein the first wall is angularly oriented relative to the second wall.

16. The hearth of claim 14 , wherein the cavity comprises a skull of material, and wherein the skull of material defines an angled geometry between the first end portion and the second end portion.

17. The hearth of claim 14 , wherein the outlet is a first outlet, the hearth comprises a second outlet that defines an outlet capacity, and a sum of the outlet capacities of the first outlet and the second outlet substantially matches the inlet capacity.

18. The hearth of claim 17 , wherein the cavity defines a longitudinal axis, and wherein the first outlet and the second outlet are symmetrically arranged relative to the longitudinal axis.

19. The hearth of claim 14 , wherein the inlet comprises an inlet low edge, the outlet comprises an outlet low edge, and the outlet low edge is higher than the inlet low edge.

20. A casting system comprising:
an energy source; and
a hearth including a sidewall and a skull of material integrally formed in the hearth, wherein the skull of material comprises:
an inlet defining an inlet cross-sectional area, the inlet defined through the sidewall,
an outlet defining an outlet cross-sectional area, the outlet defined through the sidewall, and
a cavity between the inlet and the outlet, wherein the cavity defines a cavity cross-sectional area that is continually reduced from the inlet toward the outlet.

21. The casting system of claim 20 , wherein the inlet defines an inlet cross-sectional area, and wherein the outlet defines an outlet cross-sectional area less than the inlet cross-sectional area.

22. The casting system of claim 20 , wherein the inlet comprises an inlet low edge, the outlet comprises an outlet low edge, and the outlet low edge is higher than the inlet low edge.

23. The casting system of claim 20 , wherein the skull comprises a plurality of outlets, and wherein the sum of outlet cross-sectional areas substantially matches the inlet cross-sectional area.

24. An apparatus for use with a casting system, the apparatus comprising:
a hearth comprising a sidewall; and
a skull of material integrally formed in the hearth, wherein the skull of material comprises:
an inlet defining an inlet cross-sectional area, the inlet defined through the sidewall,
an outlet defining an outlet cross-sectional area, the outlet defined through the sidewall, and
a cavity between the inlet and the outlet, wherein the cavity defines a cavity cross-sectional area that is continually reduced from the inlet toward the outlet.

25. The apparatus of claim 24 , wherein the inlet defines an inlet cross-sectional area, and wherein the outlet defines an outlet cross sectional area less than the inlet cross-sectional area.

26. The apparatus of claim 24 , wherein the inlet comprises an inlet low edge, the outlet comprises an outlet low edge, and the outlet low edge is higher than the inlet low edge.

27. The apparatus of claim 24 , wherein the skull comprises a plurality of outlets, and wherein the sum of outlet cross-sectional areas substantially matches the inlet cross-sectional area.

Assignees

• Ati Properties Inc
• Ati Properties Llc

Inventors

• Copland Evan H
• Arnold Matthew J
• Minisandram Ramesh S

Classifications

• B22D11/0403 Primary

  Multiple moulds · CPC title

• B22D11/116 Primary

  Refining the metal · CPC title

• F27D9/00

  Cooling of furnaces or of charges therein (casings, linings, walls or roofs incorporating cooling arrangements F27D1/12) · CPC title

• F27D2009/0002

  Cooling of furnaces · CPC title

• B22C9/08

  Features with respect to supply of molten metal, e.g. ingates, circular gates, skim gates · CPC title