Patent ID: 7896059

Claim:
A metal casting system ( 1 ) for continuous delivery of molten metal in a controlled environment, comprising: a melting furnace ( 2 ) having a molten metal surface and an inert furnace atmosphere throughout the entire casting system, wherein said inert furnace atmosphere is inert to the metal being cast; a pressurized metal delivery vessel ( 12 ) connected to the melting furnace ( 2 ) with a discharge opening dam ( 6 ) for maintaining a production level ( 4 ) of molten metal to continuously deliver clean, oxide-free metal from below the molten metal surface; a treatment vessel ( 5 ) connected between the melting furnace and the metal delivery vessel to provide a continuous supply of molten metal from the melting furnace to the metal delivery vessel; a transfer valve ( 9 ) that allows metal flow from the melting furnace to the metal delivery vessel, wherein the transfer valve includes a stopper rod made of steel and a filter made of steel to facilitate continuous pouring; and an engineered sand mold comprising a binder for receiving molten metal from the pressurized metal delivery vessel, wherein said engineered sand mold is at least partially encapsulated to contain a significantly reduced amount of sand in the sand mold and facilitating maintenance of a controlled atmosphere with inert gases, wherein a gas impermeable exterior barrier layer incorporated into the exterior surface of the engineered mold, the exterior barrier layer provides environmental isolation from the ambient atmosphere; and a source of inert gas connected to the engineered sand mold.