Method of making a casting having a low density insert

Details Method of making a casting having a low density insert Method of making a casting having a low density insert

1996-04-16

1999-11-30

Lin, Kuang Y.

Metal founding

Process

Shaping liquid metal against a forming surface

164 79, B22D 1900

Patent

active

059925000

ABSTRACT:
A composite metallic cast article (A) includes a shell (28) having a predetermined solid phase density. A non removable insert (24) is at least partially embedded within the shell (28). The insert (24) is fabricated from a foamed metal substance having a substantially lower solid phase density than the shell (28). The foamed metal insert (24) may have a layer of skin (26) fused with the molten metal of the shell (28) during the casting process. Tapered locating pins (30) or other spacing elements position the insert (24) within the mold cavity (18) to prevent shift during the casting operation. The foamed metal insert (24) reduces the time and expense involved in removing a traditional casting core after the casting operation is complete. Also, the insert (24) can be completely enclosed within the shell (28) of the article (A), thereby expanding the design capabilities of such cast articles (A). Furthermore, the foamed metal insert (24) provides better stiffness and energy absorbsion to the cast article (A) when compared with a hollow cavity section formed by a core of the prior art.

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Practice & Management (PMI vol. 25, No. 4, 1993); "P/M Technology for the Production of Metal Foams" by H.-D. Kunze, J. Baumeister, J. Banhart, and M. Weber.
Mepura Metallpulvergesellschaft m.b.H. Ranshofen; "Alulight" Advertisement Materials (Jun. 1996).

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