Methods and apparatus for heat treatment and sand removal for castings

Abstract

A system and method for heat treating castings and removing sand cores therefrom. The castings are initially located in indexed positions with their x, y, and z coordinates known. The castings are passed through a heat treatment station typically having a series of nozzles mounted in preset positions corresponding to the known indexed positions of the castings passing through the heat treatment station. The nozzles apply heat to the castings for heat treating the castings and dislodging the sand cores for removal from the castings.

1 . A system for processing a metal casting comprising: 
 a first heat source for pre-heating a mold to a desired pre-heating temperature for a molten metal to be cast;    a pouring station for pouring the molten metal into the pre-heated mold;    a process control temperature station downstream from said pouring station, said process control temperature station including a second heat source for maintaining the metal at or above a process control temperature for the metal as the metal at least partially solidifies to form the casting; and    a heat treatment station in which the at least partially solidified metal is at least partially heat treated while the casting is within the mold;    wherein the process control temperature for the metal is the temperature below which for every one minute of time the temperature of the casting decreases, more than one minute of heat treatment is required to attain the desired properties of the casting.    
   
   
       2 . The system of  claim 1 , wherein said heat treatment station comprises at least one nozzle initially mounted in alignment with a plurality of openings in the mold for applying a fluid to the mold.  
   
   
       3 . The system of  claim 1 , wherein at least one of said process control temperature station and said heat treatment station comprises a radiant energy source for heating the mold and casting therewithin.  
   
   
       4 . The system of  claim 1 , wherein at least one of said process control temperature station and said heat treatment station comprises an induction energy source for heating the mold and casting therewithin.  
   
   
       5 . The system of  claim 1 , wherein said heat treatment station comprises a pressurized chamber for drawing a flow of oxygen gas through the mold for reacting and combusting with a binder material to at least partially heat treat the castings within the mold as the binder material and oxygen gas are combusted.