Patent ID: 6554056
Filing Date: 2003-04-29
Classification: B22C,B33Y

Abstract:
A method of forming and modifying one or more sand mold elements of a sand mold assembly, the sand mold assembly having an internal cavity adapted to be filled with molten material for forming a metal casting, the method comprising:molding and patterning sand into shapes of the sand mold elements with at least one master pattern to provide a first mold assembly, the sand mold elements interfitting together to define the internal cavity; forming a first metal casting with the first mold assembly; determining that the first metal casting formed with the first mold assembly has a flaw; selecting at least one area on the at least one sand mold element for a machining operation to remedy said flaw; molding and patterning sand into shapes of the sand mold elements with at least one master pattern to provide a second mold assembly; machining the at least one area of at least one of the sand mold elements of the second mold assembly to modify the shape of the internal cavity; and forming a second metal casting with the second mold assembly.