Abstract:
An apparatus and method for quiescently filling of a ladle with molten material and transferring of the molten material from the ladle is disclosed, wherein the molten material is transferred from the ladle to a casting mold to minimize turbulence in the molten material to minimize defects in a desired cast object.

Description:
FIELD OF THE INVENTION 
       [0001]    This invention relates to an apparatus and method for the quiescent-fill of a ladle and the transfer of a molten material from the ladle to a casting mold to minimize turbulence in the molten material to minimize defects in a desired cast object formed by a tilt pour molding process. 
       BACKGROUND OF THE INVENTION 
       [0002]    The pouring of a molten material, such as metal, for example, into a casting mold is a significant process variable that influences the internal soundness, surface conditions, and mechanical properties, such as tensile strength, porosity, percent elongation and hardness, of a cast object. Many different designs for dipping/pouring ladles exist and are used in the foundry industry. The designs are normally chosen based upon the type of molten material and casting mold used. Commonly used ladles make use of a slot, a lip and a baffle, or a dam at the top of the ladle to reduce inclusion of furnace metal oxides during metal filling, or the ladle may incorporate a stopper rod to control the flow of metal into and out of the ladle. 
         [0003]    Molten metals, such as aluminum, for example, react with the air and create oxides, commonly known as dross, which upon mixing with the rest of the molten metal creates inclusions and highly porous regions in the cast object during solidification of the metal. While many factors influence and account for undesirable properties in the cast object, two common sources of inclusions include formation of a dross layer on top of the molten metal, and the folding action of the molten metal caused by turbulent flow of the molten metal during pouring. Turbulent metal flow exposes the molten metal surface area to the air which creates the dross layer. Depending on the velocity of the molten metal, dictated by the pouring ladle and basin design and use, the molten metal may fold-over itself many times, thereby trapping oxygen and metal oxide layers therein and exposing additional surface area of the metal to the air. 
         [0004]    Typical foundry ladles are referred to as teapot-type ladles. These ladles are substantially cylindrical in shape with an external spout extending outwardly from the top thereof. Certain teapot ladles have incorporated a wall or a baffle to separate the bowl or cavity area of the ladle from the spout. The wall or baffle may extend to the bottom of the ladle. When the molten metal is poured, the baffle restricts the flow of molten metal from the top of the ladle to facilitate the pouring of the metal that is near the bottom of the ladle. The metal at the bottom of the ladle is substantially free from dross and other foreign material that may be present, such as eroded refractory lining and ash created during a melting process of the metal. Although the baffle serves to minimize dross inclusion, the external spout design still increases the velocity of the material upon pouring, and may create turbulent flow. Next, the molten metal is typically transferred from the ladle to a casting mold through a pour basin. In traditional pour basin designs, molten material flows down the basin to a mold sprue. The flow of the molten metal through the sprue may also cause turbulence therein, thereby creating additional dross. 
         [0005]    Low pressure, bottom pour furnaces have been known to produce castings with minimized dross, but the equipment is expensive, complex, and subject to high maintenance requirements. In addition, the bottom pour furnaces increase capital costs. Hot Isostatic Pressing (HIPping) of castings may also reduce porosity in aluminum castings, however HIPping is expensive and may cause dimensional changes to the casting that may not be uniform or replicable. 
         [0006]    Thus, there remains a need for an economical method and apparatus that would prevent or minimize the inclusion of dross and contaminants leading to high porosity and/or low mechanical properties of cast materials. 
         [0007]    It would be desirable to provide an apparatus and method for the quiescent-fill of a ladle and the transfer of a molten material from the ladle to a casting mold to minimize turbulence in the molten material to minimize defects in the desired cast object formed by a tilt pour molding process. 
       SUMMARY OF THE INVENTION 
       [0008]    Concordant and congruous with the present invention, an apparatus and method for the quiescent-fill of a ladle and the transfer of a molten material from the ladle to a casting mold to minimize turbulence in the molten material to minimize defects in the desired cast object formed by a tilt pour molding process, have surprisingly been discovered. 
         [0009]    In one embodiment, a casting apparatus comprises a ladle having a hollow interior adapted to receive a molten material therein, wherein said ladle is adapted to pivot about an eccentric axis; and a mold having a cavity formed therein adapted to receive the molten material, wherein said ladle abuts said mold, and said mold and said ladle are cooperatively rotated to pour the molten material from said ladle into the cavity of said mold. 
         [0010]    In another embodiment, a casting apparatus comprises a ladle having a hollow interior adapted to receive a molten material therein, said ladle having an aperture formed therein, wherein said ladle is adapted to pivot about an eccentric axis; and a mold having a cavity formed therein adapted to receive the molten material, wherein said ladle abuts said mold, and said mold and said ladle are cooperatively rotated to pour the molten material from said ladle into the cavity of said mold. 
         [0011]    In another embodiment, a method of transferring a molten material to a casting mold, the method comprises providing a ladle having a hollow interior adapted to receive a molten material therein, the ladle having an aperture formed therein, wherein the ladle is adapted to rotate about an eccentric axis; providing a mold having a cavity formed therein adapted to receive the molten material, wherein the ladle abuts the mold and the mold and the ladle are cooperatively rotated to pour the molten material from the ladle into the cavity of the mold; filling the ladle with the molten material; positioning the aperture of the ladle adjacent the cavity of the mold; and rotating the mold and ladle to facilitate the pouring of the molten material from the ladle into the cavity of the mold. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0012]    The above, as well as other advantages of the present invention, will become readily apparent to those skilled in the art from the following detailed description of a preferred embodiment when considered in the light of the accompanying drawings in which: 
           [0013]      FIG. 1  is a perspective view of a molding apparatus including a ladle and a mold rotated ninety degrees according to an embodiment of the invention; 
           [0014]      FIG. 2  is a perspective view of the ladle of  FIG. 1 ; and 
           [0015]      FIG. 3  is a perspective view of a molding apparatus including a ladle and a mold rotated ninety degrees according to another embodiment of the invention. 
       
    
    
     DETAILED DESCRIPTION OF THE EMBODIMENTS 
       [0016]    The following detailed description and appended drawings describe and illustrate various exemplary embodiments of the invention. The description and drawings serve to enable one skilled in the art to make and use the invention, and are not intended to limit the scope of the invention in any manner. In respect of the methods disclosed, the steps presented are exemplary in nature, and thus, the order of the steps is not necessary or critical. 
         [0017]      FIG. 1  shows a casting apparatus  10  according to an embodiment of the invention. The casting apparatus  10  includes ladle  12  adapted to receive a molten material  16  therein and to pour the molten material  16  therefrom. A mold  14  is provided in fluid communication with the ladle  12  and is adapted to receive the molten material  16  therefrom. It is understood that the molten material  16  may be any molten material such as a metal or a polymer, for example, as desired. 
         [0018]    The ladle  12  is a quiescent-fill ladle similar to the ladle disclosed in commonly owned U.S. Pat. No. 7,025,115, hereby incorporated herein by reference in its entirety. As used herein, the term “quiescent-fill” is defined as a ladle adapted to receive a molten material therein with a minimized amount of turbulence, agitation, and folding of the molten material. The ladle  12  may be formed from any conventional material such as a ceramic or a metal, for example, as desired. In the embodiment shown in  FIGS. 1 and 2 , the ladle  12  includes a hollow interior  26 . The ladle  12  is formed by a pair of planar side walls  18 , a substantially planar front wall  28 , and a curvilinear wall  30 . The side walls  18  are each defined by a curvilinear edge  20 , a first rectilinear edge  22 , and a second rectilinear edge  24 . The second rectilinear edge  24  is adapted to abut the mold  14 . Each side wall  18  includes an pin  32  formed thereon. In the embodiment shown, the pins  32  are adapted to facilitate a pivoting of the ladle  12  about an eccentric axis of rotation of the ladle  12  such that the front wall  28  pivots downwardly when the ladle  12  is filled with a molten material. It is understood that the pins  32  may be formed with the side walls  18 , or the pins  32  may be separately formed and attached to the side walls  18 . 
         [0019]    The front wall  28  of the ladle  12  is adapted to substantially abut the mold  14 . A second aperture  34  is formed in the front wall  28  of the ladle  12 . In the embodiment shown, the second aperture  34  has a length substantially equal to a length of the front wall  28 . However, the second aperture  34  may have any length, as desired. A top of the front wall  28  of the ladle  12  may include a protuberant portion or lip. The protuberant portion may be formed on an exterior of the front wall  28  or the interior of front wall  28  of the ladle  12 , as desired. The curvilinear wall  30  forms a bottom wall and a back wall of the ladle  12 . However, the bottom wall and back wall of the ladle  12  may be formed from a combination of a substantially planar wall and a curvilinear wall, a pair of substantially planar walls, or a pair of curvilinear walls, as desired. 
         [0020]    In the embodiment shown in  FIG. 1 , the mold  14  is adapted to receive a molten material therein through a tilt-pour process. The mold  14  includes a body portion  36  forming a cavity  38  therein. A length of the cavity  38  is substantially equal to the length of the second aperture  34  formed in the front wall  28  of the ladle  12 . The cavity  38  of the mold  14  may have the shape of any desired cast object, such as an engine block, a cylinder head, a complex transmission component, and the like, for example. The mold  14  also includes risers  40  adapted to form reservoirs that militate against the formation of cavities or voids in the desired cast object due to shrinkage of the molten material  16  during a cooling and solidification thereof. 
         [0021]    In use, the ladle  12  is filled with the molten material  16  during a filling operation which includes: (1) positioning the ladle  12  in a rest position over a furnace dip well or crucible (not shown) filled with the molten material  16 ; (2) lowering the ladle  12  to the surface of the molten material  16  and making initial contact between the ladle  12  and the molten material  16 ; (3) rotating the ladle  12  about the eccentric axis on the pins  32  and exposing a portion of the aperture  34  to the molten material  16 , thereby minimizing the drop of the molten material  16  into the ladle  12  during filling; (4) lowering the ladle  12  to a desired depth into the crucible; (5) rotating the ladle  12  back to the rest position; and (6) raising the ladle  12  containing molten material  16  from the crucible. By minimizing the drop of the molten material  16  into the ladle  12 , turbulent flow of the molten material  16  into the ladle  12  and the folding of the molten material  16  therein is minimized. 
         [0022]    As shown in  FIG. 1 , the mold  14  is rotated ninety degrees in respect of a floor or a surface parallel to the floor with a top of the cavity  38  thereof substantially perpendicular to the front wall  28  of the ladle  12 . The second aperture  34  of the ladle  12  is positioned adjacent the cavity  38 , with the front wall  28  of the ladle  12  abutting the mold  14 . It is understood that the ladle  12  may be positioned adjacent to the cavity  38  with a small gap between the front wall  28  and the mold  14 . The ladle  12  and the adjacent mold  14  are then rotated or otherwise controlled in unison, either secured together with attaching means (not shown) or by synchronized control of the ladle  12  and mold  14  together. The casting apparatus  10 , which includes the ladle  12  and mold  14 , is then caused to rotate ninety degrees as indicated by the arrow R about the eccentric axis on the pins  32  which may be located at a junction of the ladle  12  and the mold  14  or at the base of the mold  14 , as desired. The rate of rotation of the casting apparatus  10  is regulated to facilitate a gravity-assisted, low velocity pour of the molten material  16  into the cavity  38  of the mold  14 . Since the molten material  16  is poured directly into the cavity  38  and not into a gate system, the drop of the molten material  16  from the ladle  12  and into the cavity  38  is minimized. Since turbulence and folding of the molten material  16  are minimized, entrapment of air in the molten material  16  and oxidation of the molten material  16  are minimized, thereby minimizing deformities and defects and maximizing the quality of the cast object. 
         [0023]    Once the molten material  16  has been allowed to cool and harden, the three-dimensional cast object may be removed from the mold  14 . The cast object may then be further machined to result in a final shape thereof. Additional heat treating operations, coating processes, and the like can also be conducted on the casting. 
         [0024]      FIG. 3  shows a casting apparatus  10 ′ according to another embodiment of the invention similar to the molding apparatus  10  of  FIGS. 1 and 2  except as described below. This embodiment of  FIG. 3  facilitates a ladle  12  width that does not cover the entire width of the cavity  38  of the mold  14 . Having a ladle  12  with a width less than the width of the cavity  38  is desired when the cavity  38  of the mold  14  is so wide that a ladle having a matching width would be cumbersome to handle and difficult to fill with a dipping well or crucible. This embodiment allows for a reduced ladle width without the risk of spilling metal out of the open mold areas. Like structure from  FIGS. 1 and 2  repeated in  FIG. 3  includes identical reference numerals accompanied by a prime (′) symbol. 
         [0025]    The casting apparatus  10 ′ includes a ladle  12 ′ adapted to receive and pour a molten material  16 ′. A mold  14 ′ is adapted to receive the molten material  16 ′ from the ladle  12 ′. It is understood that the molten material  16 ′ may be any molten material such as a metal or a polymer, for example, as desired. 
         [0026]    The ladle  12 ′ may be formed from any conventional material such as a ceramic or a metal, for example, as desired. In the embodiment shown, the ladle  12 ′ includes a hollow interior  26 ′ formed by a pair of planar side walls  18 ′, a substantially planar front wall  28 ′, and a curvilinear wall  30 ′. The side walls  18 ′ are each defined by a curvilinear edge  20 ′, a first rectilinear edge  22 ′, and a second rectilinear edge  24 ′. The second rectilinear edge  24 ′ is adapted to abut the mold  14 ′. Each side wall  18 ′ includes a pin  32 ′ formed thereon. In the embodiment shown, the pins  32 ′ are adapted to facilitate the rotation of the ladle  12 ′ on the pins  32 ′ about an eccentric axis of rotation of the ladle  12 ′. It is understood that the pins  32 ′ may be formed with the side walls  18 ′, or the pins  32 ′ may be separately formed and attached to the side walls  18 ′. However, the bottom wall and back wall of the ladle  12 ′ may be formed from a combination of a rectilinear wall and a curvilinear wall, a pair of rectilinear walls, or a pair of curvilinear walls, as desired. 
         [0027]    The front wall  28 ′ of the ladle  12 ′ is adapted to substantially abut the mold  14 ′. A second aperture  34 ′ is formed in the front wall  28 ′ of the ladle  12 ′. In the embodiment shown, the second aperture  34 ′ has a length substantially equal to a length of the front wall  28 ′, but the second aperture  34 ′ may have any length, as desired. A top of the front wall  28 ′ of the ladle  12 ′ may include a protuberant portion or lip. The protuberant portion may be formed on an exterior of the front wall  28 ′ or the interior of front wall  28 ′ of the ladle  12 ′, as desired. The curvilinear wall  30 ′ defines a bottom wall and a back wall of the ladle  12 ′. 
         [0028]    In the embodiment shown in  FIG. 3 , the mold  14 ′ is adapted to receive a molten material therein through a tilt-pour process. The mold  14 ′ includes a body portion  36 ′ forming a cavity  38 ′ therein and a pair of mold features  42  adapted to militate against a spilling of the molten material  16 ′ from the mold cavity  38 ′ during the tilt-pour process. A length of the cavity  38 ′ is longer than the length of the second aperture  34 ′ formed in the front wall  28 ′ of the ladle  12 ′. The cavity  38 ′ of the mold  14 ′ may have the shape of any desired cast object, such as an engine block, a cylinder head, a complex transmission component, and the like, for example. The mold features  42  are disposed adjacent to the side walls  18 ′ of the ladle  12 ′ when the ladle  12 ′ is disposed adjacent to the mold  14 ′. The mold features have a height greater than the height of the portion of the mold cavity  38 ′ disposed adjacent to the ladle  12 ′. The dimensions of the mold features  42  will vary based on the design of the ladle  12 ′ and the rate at which the ladle  12 ′ and the mold  14 ′ are rotated during the tilt-pour process. As the rate of rotation increases, the rate of pouring of the molten material  16 ′ increases, thereby increasing the height of the molten material  16 ′ in the mold cavity  38 ′ to a height above the aperture  34 ′ of the ladle  12 ′. As the height of the molten material  16 ′ in the mold cavity  38 ′ increases, the dimensions of the mold features  42  increase to militate against spilling. The mold  14 ′ also includes risers  40 ′ adapted to form reservoirs that militate against the formation of cavities or voids in the desired cast object due to shrinkage of the molten material  16 ′ during a cooling and solidification thereof. 
         [0029]    In use, the ladle  12 ′ is filled with the molten material  16  during a filling operation which includes: (1) positioning the ladle  12 ′ in a rest position over a furnace dip well or crucible (not shown) filled with the molten material  16 ′; (2) lowering the ladle  12 ′ to the surface of the molten material  16 ′ and making initial contact between the ladle  12 ′ and the molten material  16 ′; (3) rotating the ladle  12 ′ about the eccentric axis on the pins  32 ′ and exposing a portion of the aperture  34 ′ to the molten material  16 ′, thereby minimizing the drop of the molten material  16 ′ into the ladle  12 ′ during filling; (4) lowering the ladle  12 ′ to a desired depth into the crucible; (5) rotating the ladle  12 ′ back to the rest position; and (6) raising the ladle  12 ′ containing molten material  16 ′ from the crucible. By minimizing the drop of the molten material  16 ′ into the ladle  12 ′, turbulent flow of the molten material  16 ′ into the ladle  12 ′ and the folding of the molten material  16 ′ therein is minimized. 
         [0030]    As shown in  FIG. 3 , the mold  14 ′ is rotated ninety degrees in respect of the floor or a surface parallel to the floor with a top of the cavity  38 ′ substantially perpendicular to the ladle  12 ′. The second aperture  34 ′ of the ladle  12 ′ is positioned adjacent the cavity  38 ′, with the front wall  28 ′ of the ladle  12 ′ abutting the mold  14 ′. It is understood that the ladle  12 ′ may be positioned adjacent to the cavity  38 ′ with a small gap between the front wall  28 ′ and the mold  14 ′. The ladle  12 ′ and the adjacent mold  14 ′ are then rotated or otherwise controlled in unison, either secured together with attaching means (not shown) or by synchronized control of the ladle  12 ′ and mold  14 ′ together. The casting apparatus  10 ′, which includes the ladle  12 ′ and mold  14 ′, is then caused to rotate ninety degrees as indicated by the arrow R′ about the eccentric axis on the pins  32 ′ which may be located at a junction of the ladle  12 ′ and the mold  14 ′ or at the base of the mold  14 ′, as desired. The rate of rotation of the casting apparatus  10 ′ is regulated to facilitate a gravity-assisted, low velocity pour of the molten material  16 ′ into the cavity  38 ′ of the mold  14 ′. As the molten material  16 ′ enters the cavity  38 ′, the molten material  16 ′ flows therethrough filling void space in the cavity  38 ′ until filled to a desired level. Since the molten material  16 ′ is poured directly into the cavity  38 ′ and not into a gate system, the drop of the molten material  16 ′ from the ladle  12 ′ and into the cavity  38 ′ is minimized, thereby minimizing the turbulent flow and the folding thereof. Since turbulence and folding of the molten material  16 ′ are minimized, entrapment of air in the molten material  16 ′ and oxidation of the molten material  16 ′ are minimized, thereby minimizing the deformities and maximizing the quality of the cast object. 
         [0031]    Once the molten material  16 ′ has been allowed to cool and harden, the three-dimensional cast object may be removed from the mold  14 ′. The cast object may then be further machined to result in a final shape thereof. Additional heat treating operations, coating processes, and the like can also be conducted on the casting. 
         [0032]    The foregoing discussion discloses and describes merely exemplary embodiments of the present invention. One skilled in the art will readily recognize from such discussion and from the accompanying drawings and claims that various changes, modifications and variations can be made therein without departing from the spirit and scope of the invention as defined in the following claims.