Method of Casting an Article

Abstract

A method of casting an article using a mold including a mold cavity, the method including the steps of providing a compound containing a halogen at at least a portion of a surface of the mold adjacent the mold cavity, pouring molten metal into the mold cavity and allowing the metal to cool and solidify, and removing the article from the mold.

1 . A method of casting an article using a mold including a mold cavity, comprising: 
 providing a halogen-containing compound at at least a portion of a surface of the mold adjacent the mold cavity;    pouring molten metal into the mold cavity;    cooling and solidifying the metal; and    removing the article from the mold.    
   
   
       2 . A method according to  claim 1 , wherein the halogen comprises fluorine.  
   
   
       3 . A method according to  claim 2 , wherein the halogen-containing compound comprises dipotassium fluorotitanate.  
   
   
       4 . A method according to  claim 1 , wherein the halogen comprises chlorine.  
   
   
       5 . A method according to  claim 4 , wherein the halogen-containing compound comprises a potassium chloride-magnesium chloride eutectic.  
   
   
       6 . A method according to  claim 1 , wherein the halogen-containing compound is provided in a coating applied to at least a portion of a surface of the mold forming at least part of the mold cavity.  
   
   
       7 . A method according to  claim 1 , wherein the method further comprises the step of subjecting the article to isostatic pressure.  
   
   
       8 . A method according to  claim 7 , wherein the method further comprises the step of maintaining the article at an elevated temperature at which the entire article remains solid while applying the isostatic pressure.  
   
   
       9 . A method according to  claim 1 , wherein the step of providing a halogen-containing compound at at least a portion of a surface of the mold comprises spraying the halogen-containing compound onto the mold.  
   
   
       10 . A method according to  claim 1 , wherein the mold is made predominantly from sand.  
   
   
       11 . A method according to  claim 1 , wherein the article is an engine block.  
   
   
       12 . A method according to  claim 11 , wherein the portions of the mold cavity surface that are coated with the halogen-containing compound form cylinders in the engine block.  
   
   
       13 . A method of casting an article using a mold including a mold cavity, comprising: 
 providing a halogen-containing compound at at least a portion of a surface of the mold adjacent the mold cavity;    pouring molten metal into the mold cavity, the metal mostly comprising aluminum;    cooling and solidifying the metal; and    removing the article from the mold.    
   
   
       14 . A method according to  claim 13 , wherein the metal comprises an aluminum-silicon alloy.  
   
   
       15 . A method according to  claim 14 , wherein the metal comprises a hypoeutectic aluminum-silicon alloy.  
   
   
       16 . A method according to  claim 13 , wherein the halogen-containing compound comprises dipotassium fluorotitanate.  
   
   
       17 . A method according to  claim 13 , wherein the halogen-containing compound comprises a potassium chloride-magnesium chloride eutectic.  
   
   
       18 . A method according to  claim 13 , wherein the halogen-containing compound is provided in a coating applied to at least a portion of a surface of the mold forming at least part of the mold cavity.  
   
   
       19 . A method according to  claim 13 , wherein the method further comprises the step of subjecting the article to isostatic pressure.  
   
   
       20 . A method according to  claim 19 , wherein the method further comprises the step of maintaining the article at an elevated temperature at which the entire article remains solid while applying the isostatic pressure.  
   
   
       21 . A cast article formed according to the following steps: 
 providing a mold defining a mold cavity;    providing a halogen-containing compound at at least a portion of a surface of the mold adjacent the mold cavity;    pouring molten metal into the mold cavity;    cooling and solidifying the metal; and    removing the article from the mold.