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 fluid to the castings for heat treating the castings and degrading the sand cores for removal from the castings.

1 . A method of processing a casting comprising: 
 pouring a molten material into a mold containing a core;    solidifying at least a portion of the molten material to form a casting; pre-heating the casting;    heat treating the casting; and,    degrading at least a portion of the core with a fluid flow.    
   
   
       2 . The method of  claim 1 , further comprising opening the mold to expose the casting to a pre-heating environment.  
   
   
       3 . The method of  claim 1 , further comprising removing the casting from the mold.  
   
   
       4 . The method of  claim 1 , wherein the casting is maintained in a closed mold during pre-heating.  
   
   
       5 . The method of  claim 1 , wherein pre-heating the casting includes exposing the casting to energy selected from inductive energy, radiant energy and combinations thereof.  
   
   
       6 . The method of  claim 1 , further comprising directing fluid flows at the casting from a series of nozzles.  
   
   
       7 . The method of  claim 6 , further comprising aligning the series of nozzles with openings in the casting.  
   
   
       8 . The method of  claim 1 , wherein the fluid flow comprises a fluid media selected from air, water, steam, organic solvents, thermal oils and combinations thereof.  
   
   
       9 . The method of  claim 8 , wherein the fluid flow is heated.  
   
   
       10 . The method of  claim 1 , wherein the core comprises a binder that is soluble in the fluid flow.  
   
   
       11 . The method of  claim 1 , wherein the casting is exposed to energy selected from inductive energy, radiant energy and combinations thereof during heat treating.  
   
   
       12 . The method of  claim 1 , further comprising quenching the casting.  
   
   
       13 . The method of  claim 12 , wherein quenching comprises exposing the casting to a fluid flow to degrade the core.  
   
   
       14 . The method of  claim 13 , wherein the core comprises a binder that is soluble in the fluid flow.  
   
   
       15 . The method of  claim 14 , wherein the fluid flow comprises water, air, steam, organic solvents, thermal oils and combinations thereof.  
   
   
       16 . The method of  claim 1 , further comprising aging the casting.  
   
   
       17 . The method of  claim 1 , further comprising adjusting the temperature of the mold prior to pouring the molten material therein.  
   
   
       18 . The method of  claim 17 , wherein adjusting the temperature of the mold includes heating the die.  
   
   
       19 . The method of  claim 17 , wherein adjusting the temperature of the mold includes cooling the die.  
   
   
       20 . A method of processing a casting comprising: 
 pouring a molten material into a mold containing a core;    solidifying at least a portion of the molten material to form a casting; heat treating the casting while the casting is in the die; and,    degrading the core with a fluid flow, wherein the core comprises a binder that is soluble in the fluid flow.    
   
   
       21 . The method of  claim 20 , wherein the fluid flow comprises air, water, steam, organic solvents, thermal oils and combinations thereof.  
   
   
       22 . The method of  claim 20 , further comprising pre-heating the casting.  
   
   
       23 . The method of  claim 20 , further comprising adjusting the temperature of the mold prior to pouring molten material therein.  
   
   
       24 . The method of  claim 23 , wherein adjusting the temperature of the mold comprises heating the mold.  
   
   
       25 . The method of  claim 23 , wherein adjusting the temperature of the mold comprises cooling the mold.  
   
   
       26 . The method of  claim 20 , further comprising aligning a nozzle with an opening in the casting, wherein the fluid flow is directed from the nozzle.  
   
   
       27 . The method of  claim 20 , wherein degrading the core with the fluid flow comprises quenching the casting with the fluid flow.  
   
   
       28 . The method of  claim 20 , wherein degrading the core with the fluid flow comprises pre-heating the casting with the fluid flow.