US3895672A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Integrated furnace method and apparatus for the continuous production of individual castings
Assignee: RTX Corp
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Filing: 1973-12-26
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Granted: 1975-07-22
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Expires: 1993-12-26
Abstract
Abstract An apparatus and method for forming and casting metal alloys on a continuous basis in an integrated furnace system are disclosed. A highly flexible manipulator and a plurality of solidification cells are integrated in a main chamber to enable the manipulator to service all the solidification locations, each of which has the capability to control the solidification of an individual casting independent of the solidification occurring in the remaining cells. A bulk material container interfaces with the main chamber to form a melting and pouring station at the interface. Electron beam means provide high density power at controlled rates to a suitable location at which the metal alloy is melted with precision and poured from a crucible. In the operation of the furnace, the manipulator forms an assembly from a mold and a casting plate, delivers the assembly to the melting station where it is filled, delivers the filled assembly to a solidification cell where the alloy is cooled under controlled conditions and then removes the assembly to a discharge chute. The solidification process is the operation of longest time interval and while any given assembly is being cooled in a solidification cell, the manipulator is generally engaged elsewhere in the furnace system. After a vacancy has occurred in a cell, the manipulator delivers a new assembly for solidification and the furnace system is operated continuously for an essentially indefinite period.
Inventors
- 👤 Jr Robert E King
- 👤 Bruce E Terkelsen
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-09 03:55
CPC Classifications
B; B22; B22D; B22D27/00; B22D27/15; B22D27/04; B22D27/045
Claims Analysis
Total Claims: 18
Claim 1
Independent Claim
406 words
An intergrated furnace system for the continuous production of individual castings comprising: a main chamber having a controllable internal atmosphere; means for providing a controlled atmosphere in the main chamber; a bulk material container adjacent to the main chamber to provide bulk material for melting, pouring and delivery to the main chamber, and including: a melting and pouring station located at the interface of the main chamber and the bulk container; and means for melting the bulk material; a manipulator positioned internal of the main chamber and capable of rotational and translational motions sufficient to provide access of the manipulator to multiple locations within the main chamber; a fresh mold feeder chute which is joined to, and penetrates the side of, the main chamber and includes: an open end which is fixedly attached to the main chamber to permit the delivery of fresh molds into the main chamber; an entry interlock to permit fresh molds to be admitted into the mold feeder chute from the surrounding environment without destroying the controlled atmosphere within the main chamber; a conveyer for transporting molds from the interlock to the main chamber; and heater elements internal of the chute to raise the temperature of the molds prior to entry into the main chamber; a casting discharge chute which is joined to, and penetrates the side of, the main chamber and includes: an open end which is fixedly attached to the main chamber to permit the removal of solidified castings from the main chamber; an exit interlock to permit solidified castings to be removed from the discharge chute to the surrounding environment without destroying the controlled atmosphere within the main chamber; a conveyer for transporting the solidified castings from the main chamber to the exit interlock; and first cooling means internal of the discharge chute to lower the temperature of the castings; a casting plate feed chute which is joined to, and penetrates the side of, the main chamber and includes: an open end which is fixedly attached to the main chamber to permit the delivery of casting plates to the main chamber; an atmospheric entry interlock to permit fresh plates to be admitted into the casting plate chute from the surrounding environment withoug destroying the controlled atmosphere in the main chamber; and a conveyer for transporting the plates from the atmospheric interlock to the main chamber; and solidification cells integral with the main chamber for controlled cooling of the castings.
Claim 2
Dependent Claim
406 words
An intergrated furnace system for the continuous production of individual castings comprising: a main chamber having a controllable internal atmosphere; means for providing a controlled atmosphere in the main chamber; a bulk material container adjacent to the main chamber to provide bulk material for melting, pouring and delivery to the main chamber, and including: a melting and pouring station located at the interface of the main chamber and the bulk container; and means for melting the bulk material; a manipulator positioned internal of the main chamber and capable of rotational and translational motions sufficient to provide access of the manipulator to multiple locations within the main chamber; a fresh mold feeder chute which is joined to, and penetrates the side of, the main chamber and includes: an open end which is fixedly attached to the main chamber to permit the delivery of fresh molds into the main chamber; an entry interlock to permit fresh molds to be admitted into the mold feeder chute from the surrounding environment without destroying the controlled atmosphere within the main chamber; a conveyer for transporting molds from the interlock to the main chamber; and heater elements internal of the chute to raise the temperature of the molds prior to entry into the main chamber; a casting discharge chute which is joined to, and penetrates the side of, the main chamber and includes: an open end which is fixedly attached to the main chamber to permit the removal of solidified castings from the main chamber; an exit interlock to permit solidified castings to be removed from the discharge chute to the surrounding environment without destroying the controlled atmosphere within the main chamber; a conveyer for transporting the solidified castings from the main chamber to the exit interlock; and first cooling means internal of the discharge chute to lower the temperature of the castings; a casting plate feed chute which is joined to, and penetrates the side of, the main chamber and includes: an open end which is fixedly attached to the main chamber to permit the delivery of casting plates to the main chamber; an atmospheric entry interlock to permit fresh plates to be admitted into the casting plate chute from the surrounding environment withoug destroying the controlled atmosphere in the main chamber; and a conveyer for transporting the plates from the atmospheric interlock to the main chamber; and solidification cells integral with the main chamber for controlled cooling of the castings.
Claim 3
Dependent Claim
16 words
The invention according to claim 1 wherein the solidification cells are internal to the main chamber.
Claim 4
Dependent Claim
28 words
The invention according to claim 1 wherein the bulk container includes further means for feeding the bulk material into the melting and pouring station at a controlled rate.
Claim 5
Dependent Claim
18 words
The invention according to claim 3 wherein the means for melting the bulk material comprises electron beam means.
Claim 6
Dependent Claim
23 words
The invention according to claim 4 wherein the bulk container includes further a crucible for collecting and containing the bulk material during melting.
Claim 7
Dependent Claim
19 words
The invention according to claim 5 wherein the casting plate is a chill plate having a high thermal conductivity.
Claim 8
Dependent Claim
18 words
The invention according to claim 5 wherein the casting plate is a material having a low thermal conductivity.
Claim 9
Dependent Claim
15 words
The invention according to claim 6 wherein the solidification cell is a directional solidification cell.
Claim 10
Independent Claim
149 words
The method of producing castings continuously in a furnace system having a conTrollable atmosphere including the steps of: providing a controlled atmosphere in the furnace; admitting a supply of casting plates into the furnace through an atmospheric interlock; admitting a supply of molds into the furnace through an atmospheric interlock; cooling the casting plates; preheating the molds; combining individual preheated molds with individual cooled casting plates to form individual mold assemblies; admitting a source of metal alloy into a melting and pouring chamber in the furnace; melting the metal alloy; collecting the melted alloy in a crucible; pouring the melted alloy into a mold assembly; inserting the filled mold assembly into a solidification cell in the furnace; soaking the filled mold assembly within the solidification cell; cooling the filled mold assembly until the metal alloy is frozen; and discharging the solidified casting from the furnace through an atmospheric interlock.
Claim 11
Independent Claim
149 words
The method of producing castings continuously in a furnace system having a conTrollable atmosphere including the steps of: providing a controlled atmosphere in the furnace; admitting a supply of casting plates into the furnace through an atmospheric interlock; admitting a supply of molds into the furnace through an atmospheric interlock; cooling the casting plates; preheating the molds; combining individual preheated molds with individual cooled casting plates to form individual mold assemblies; admitting a source of metal alloy into a melting and pouring chamber in the furnace; melting the metal alloy; collecting the melted alloy in a crucible; pouring the melted alloy into a mold assembly; inserting the filled mold assembly into a solidification cell in the furnace; soaking the filled mold assembly within the solidification cell; cooling the filled mold assembly until the metal alloy is frozen; and discharging the solidified casting from the furnace through an atmospheric interlock.
Claim 12
Dependent Claim
35 words
The process according to claim 9 further including the step of superheating the metal alloy in the crucible to a pouring temperature which is at least 400*F greater than the melting temperature of the alloy.
Claim 13
Dependent Claim
24 words
The process according to claim 9 wherein the controlled atmosphere is a vacuum condition with a pressure less than 1 X 10 3 torr.
Claim 14
Dependent Claim
23 words
The process according to claim 9 wherein the molds are preheated to a temperature greater than the melting temperature of the metal alloy.
Claim 15
Dependent Claim
39 words
The process according to claim 9 further including the setp of cooling the crucible to a temperature below the melting temperature of the metal so that a skull is formed between the crucible and the molten metal contained therein.
Claim 16
Dependent Claim
19 words
The process according to claim 13 wherein the volume of metal which is melted into the crucible is measured.
Claim 17
Dependent Claim
25 words
The process according to claim 14 wherein the filled mold assembly is maintained at a temperature greater than the melting temperature of the metal alloy.
Claim 18
Dependent Claim
33 words
The process according to claim 15 wherein the filled mold assembly is cooled to a temperature suitable to avoid oxidation and excessive thermal stresses in the casting prior to discharge from the furnace.
References Cited (Backward Citations)
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1978-07-21 | 1979-01-20 | 1979-07-22 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1982-07-21 | 1983-01-20 | 1983-07-22 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1986-07-21 | 1987-01-20 | 1987-07-22 | $7700.00 | Window Closed / Lapsed |