Short cycle casting processing

Abstract

A conveyance mechanism for transporting a casting is provided. A system and method of processing a metal casting also are provided.

1 . A conveyance mechanism for transporting a casting having a cavity, comprising: 
 a plurality of roller bars arranged transverse to an intended direction of travel of the casting;    at least one guide tube extending perpendicular to the roller bars, the at least one guide tube capable of being received within the cavity of the casting; and    a driving device in engagement with the roller bars.    
   
   
       2 . The conveyance mechanism of  claim 1 , wherein the guide tube includes an exterior surface and an interior, the interior including a bore extending along a length of the guide tube.  
   
   
       3 . The conveyance mechanism of  claim 2 , wherein the guide tube comprises a plurality of apertures extending from the bore to the exterior surface of the guide tube.  
   
   
       4 . The conveyance mechanism of  claim 3 , further comprising a source of pressurized air in communication with the bore of the guide tube.  
   
   
       5 . The conveyance mechanism of  claim 4 , wherein the apertures are positioned to impinge the casting selectively with pressurized air.  
   
   
       6 . A system for reduced-cycle heat treatment of a metal casting, comprising: 
 a pouring station for pouring a molten metal into a mold to form a casting, the mold comprising an outer mold including a casting-bearing portion;    a mold removal station comprising a pulse wave demolding system downstream from the pouring station, the demolding system capable of at least partially removing the outer mold from the casting;    a loading station comprising a conveyance mechanism that receives the demolded casting, the conveyance mechanism lacking a basket or tray for receiving the casting; and    a heat treatment station downstream from the loading station.    
   
   
       7 . The system of  claim 6 , further comprising a mold engagement device capable of engaging the casting-bearing portion of the mold.  
   
   
       8 . The system of  claim 6 , wherein the conveyance mechanism comprises: 
 a plurality of roller bars arranged transverse to an intended direction of travel of the casting;    at least one guide tube extending perpendicular to the roller bars, the at least one guide tube capable of releasably engaging the casting; and    a driving device in engagement with the roller bars.    
   
   
       9 . The system of  claim 8 , wherein the guide tube includes an exterior surface and an interior, the interior including a bore extending along a length of the guide tube, and a plurality of apertures extending from the bore to the exterior surface of the guide tube.  
   
   
       10 . The system of  claim 8 , further comprising a source of pressurized air in communication with the bore of the guide tube.  
   
   
       11 . The system of  claim 10 , wherein the apertures are positioned to impinge the casting selectively with pressurized air.  
   
   
       12 . The system of  claim 6 , further comprising a process temperature control station upstream from the heat treatment station, the process temperature control station comprising a temperature sensing device in communication with a heat source, wherein the temperature sensing device and the heat source communicate to maintain the temperature of the casting at or above a process control temperature for the metal of the casting.  
   
   
       13 . The system of  claim 5 , wherein the heat treatment station comprises: 
 a heat treatment furnace having an entry zone;    a temperature measuring device within the entry zone; and    a transfer mechanism in communication with the temperature measuring device,    wherein upon detection of a rejection temperature by the temperature measuring device, the transfer mechanism removes the casting prior to entry into said furnace.    
   
   
       14 . A method for reducing the heat treatment time of a metal casting, comprising: 
 pouring a molten metal into a mold to form a casting, the mold comprising an outer mold including a casting-bearing portion;    removing at least a portion of the outer mold using a pulse demolding system;    placing the casting on a conveyance mechanism, the conveyance mechanism capable of conveying the casting without using a basket or tray; and    heat treating the casting.    
   
   
       15 . The method of  claim 14 , further comprising removing any remaining portion of the mold prior to placing the casting on the conveyance mechanism.  
   
   
       16 . The method of  claim 14 , further comprising removing the casting-bearing portion of the mold while transferring the casting to the conveyance mechanism.  
   
   
       17 . The method of  claim 14 , further comprising maintaining the temperature of the casting at or above a process control temperature for the metal of the casting when the casting is formed until the casting is heat treated.  
   
   
       18 . A method of processing a metal casting, comprising: 
 pouring a molten metal into a mold to form a casting;    removing at least a portion of mold;    transferring the casting on a conveyance mechanism comprising: 
 a plurality of roller bars arranged transverse to an intended direction of travel of the casting;  
 at least one guide tube extending perpendicular to the roller bars, the at least one guide tube releasably engaging the casting; and  
 a driving device in engagement with the roller bars; and  
   heat treating the casting.    
   
   
       19 . The method of  claim 18 , wherein at least a portion of the mold is removed using a pulse demolding system.  
   
   
       20 . The method of  claim 18 , wherein at least a portion of the mold is removed as the casting is transferred to the conveyance mechanism.