Impact pad

Abstract

An impact pad for receiving a stream of liquid metal. The impact pad has a bottom wall with an upper surface against which the liquid metal is intended to impact. A side wall having an inner surface extends in an upward direction from the periphery of the bottom wall. The bottom wall and side wall define a metal receiving chamber having an open upper end. A plurality of spaced-apart cavities is formed in the inner surface of the side wall, the upper surface of the bottom wall or both.

1 . In an impact pad for receiving a stream of liquid metal, said impact pad having a bottom wall with an upper surface against which said liquid metal is intended to impact, a side wall having an inner surface extending in an upward direction from the periphery of said bottom wall, said bottom wall and side wall defining a metal receiving chamber having an open upper end, the improvement comprising:
 a plurality of spaced-apart cavities formed in one of the following, the inner surface of said side wall, the upper surface of said bottom wall or the inner surface of said side wall and the upper surface of said bottom wall.   
   
   
       2 . An impact pad as defined in  claim 1 , wherein said cavities are generally cylindrical in shape. 
   
   
       3 . An impact pad as defined in  claim 1 , wherein said cavities are generally spherical in shape. 
   
   
       4 . An impact pad as defined in  claim 1 , wherein said cavities are generally conical in shape. 
   
   
       5 . An impact pad as defined in  claim 1 , wherein said cavities in said side wall and said bottom wall have like configurations. 
   
   
       6 . An impact pad as defined in  claim 1 , wherein said impact pad has an outer surface that is generally cylindrical in shape. 
   
   
       7 . An impact pad as defined in  claim 1 , wherein said upper surface of said bottom wall is flat. 
   
   
       8 . An impact pad as defined in  claim 1 , wherein said metal receiving chamber is cylindrical in shape. 
   
   
       9 . An impact pad as defined in  claim 1 , wherein said cavities have a density ranging between about 6 cavities per square foot and about 1,764 cavities per square foot. 
   
   
       10 . An impact pad as defined in  claim 1 , wherein said bottom wall is generally concave. 
   
   
       11 . An impact pad as defined in  claim 1 , wherein said bottom wall is generally convex. 
   
   
       12 . An impact pad as defined in  claim 1 , wherein said side wall includes a drain opening therethrough. 
   
   
       13 . A method of forming an impact pad, comprising the steps of:
 providing an outer mold defining an inner cavity;   providing a forming mandrel having a plurality of spaced-apart projections formed on the outer surface thereof;   positioning said forming mandrel within said inner cavity, said mandrel dimensioned to form a gap between said mandrel and an inner surface of said mold;   filling said gap with a refractory castable to form a refractory shape; and   separating said forming mandrel from said mold after said refractory has hardened to release a cast refractory shape, said cast refractory shape having a cup-shape with a plurality of spaced-apart cavities along the inner surface thereof.   
   
   
       14 . A method of forming an impact pad as defined in  claim 13 , wherein said forming mandrel is cylindrical in shape and has a removable outer layer having said projections thereon. 
   
   
       15 . A method of forming an impact pad as defined in  claim 14 , wherein said projections on said outer layer are semi-spherical in shape. 
   
   
       16 . A method of forming an impact pad as defined in  claim 15 , wherein said outer layer is comprised of Bubble Wrap®. 
   
   
       17 . A method of forming an impact pad as defined in  claim 16 , wherein said outer mold is generally cup-shaped.