Method of casting metal articles

Abstract

A method of casting metal articles includes providing a plurality of interconnected support sections. Article mold sections are positioned on the support sections. After article mold cavities have been filled with a molten metal which is at a first temperature, the support sections and a body of a second molten metal are moved relative to each other while the body of a second molten metal is at a temperature which is less than the first temperature. Space extending between side surfaces of the support sections and between side portions of the article mold sections is filled with the second molten metal during movement between the support sections and the body of a second molten metal. A layer of insulating material may be provided above the body of a second molten metal. A baffle may be provided between a container holding the body of a second molten metal and a furnace assembly.

1 . A method of casting metal articles, said method comprising the steps of providing a support structure having a plurality of interconnected support sections, positioning a plurality of article mold sections on the plurality of support sections with side portions of the article mold sections extending upward from the support sections, at least partially filling article mold cavities in the article mold sections with a first molten metal which is at a first temperature while the article mold sections are supported by the support sections, thereafter, moving the support sections and a body of a second molten metal relative to each other while the body of a second molten metal is at a second temperature which is less than the first temperature, and filling space extending between the support sections and between side portions of the article mold sections with the second molten metal which forms a portion of the body of molten metal during performance of said step of moving the support sections and the body of a second molten metal relative to each other. 
   
   
       2 . A method as set forth in  claim 1  further including the steps of solidifying the first molten metal in the article mold cavities during performance of said step of moving the support sections and body of molten metal relative to each other and while the article mold sections are supported by the support sections. 
   
   
       3 . A method as set forth in  claim 1  further including the step of moving the support sections and the body of a second molten metal relative to each other for a second time, and at least partially emptying space extending between the support sections and between side portions of the article mold sections of the second molten metal during performance of said step of moving the support sections and the body of a second molten metal relative to each other for a second time. 
   
   
       4 . A method as set forth in  claim 1  further including the step of providing a layer of insulating material above the body of a second molten metal, said step of moving the support sections and the second body of molten metal relative to each other includes deflecting first portions of the layer of insulating material aligned with the support sections and leaving second portions of the layer of insulating material to extend across space between the support sections and to extend across space between side portions of the article mold sections during at least a portion of the relative movement of the support sections and body of molten metal relative to each other after deflecting the first portions of the layer of insulating material. 
   
   
       5 . A method as set forth in  claim 4  wherein the step of providing a layer of insulating material above the body of a second metal includes floating the layer of insulating material on an upper surface of the body of a second molten metal. 
   
   
       6 . A method as set forth in  claim 4  wherein said step of deflecting first portions of the layer of insulating material includes engaging the layer of insulating material and deflecting the first portions of the insulating material under the influence of force transmitted from the support sections to the first portions of the layer of insulating material. 
   
   
       7 . A method as set forth in  claim 6  wherein lower surfaces on the support sections extend parallel to upper surfaces on the support sections and said step of deflecting first portions of the layer of insulating material includes applying force against an upper side of the layer of insulating material with the lower surfaces on the support sections. 
   
   
       8 . A method as set forth in  claim 6  wherein lower surfaces on the support sections include side surface areas which extend transversely to the upper surfaces and intersect to provide a lower portion of each of the support sections with downwardly tapering configuration, said step of deflecting portions of the layer of insulating material includes deflecting insulating material in one direction with a first side surface area on the lower portion of one of the support sections and deflecting insulating material in a second direction with a second side surface area on the lower portion of said one of the support sections. 
   
   
       9 . A method as set forth in  claim 4  further including the step of retarding heat transfer with a baffle disposed between a container which holds the body of a second molten metal and a furnace assembly with the baffle disposed above and spaced from the layer of insulating material. 
   
   
       10 . A method as set forth in  claim 1  wherein each of the support sections extends outwardly from a central portion of the support structure so that the space extending between adjacent support sections increases in a direction extending outwardly from the central portion of the support structure. 
   
   
       11 . A method as set forth in  claim 1  wherein the support sections are interconnected to form a ring so that the space extending between the support sections is disposed within the ring. 
   
   
       12 . A method as set forth in  claim 1  wherein the support structure is disposed in a spatial envelope having a polygonal configuration and occupies between five percent (5%) and twenty-five percent (25%) of the area contained within the polygon forming the spatial envelope. 
   
   
       13 . A method as set forth in  claim 1  further including the step of blocking heat transfer with a baffle which is mounted on an upper end portion of a container which holds the body of a second molten metal. 
   
   
       14 . A method as set forth in  claim 13  further including the step of further blocking heat transfer with a layer of insulating material disposed on the body of a second molten metal. 
   
   
       15 . A method of casting metal articles, said method comprising the steps of providing a support structure having a plurality of interconnected support sections, positioning a plurality of article mold sections on the plurality of support sections with side portions of the article mold sections extending upward from the support sections, at least partially filling article mold cavities in the article mold sections with a first molten metal which is at a first temperature while the article mold sections are supported by the support sections, providing a layer of insulating material above a body of a second molten metal which is at a second temperature which is less than the first temperature, and moving the support sections and the body of a second molten metal relative to each other while the body of a second molten metal is at the second temperature which is less than the first temperature, said step of moving the support sections and the second body of molten metal relative to each other includes deflecting first portions of the layer of insulating material aligned with the support sections under the influence of force applied against the layer of insulating material by the support sections and leaving second portions of the layer of insulating material aligned with space extending between the support sections, said second portions of the layer of insulating material extend across space between the support sections and extend across space between side portions of the article mold sections during at least a portion of the relative movement of the support sections and body of molten metal relative to each other after deflecting the first portions of the layer of insulating material. 
   
   
       16 . A method as set forth in  claim 15  further including the steps of solidifying the first molten metal in the article mold cavities during performance of said step of moving the support sections and body of molten metal relative to each other and while the article mold sections are supported by the support sections. 
   
   
       17 . A method as set forth in  claim 15  wherein the step of providing a layer of insulating material above the body of a second metal includes floating the layer of insulating material on an upper surface of the body of a second molten metal. 
   
   
       18 . A method as set forth in  claim 15  further including the step of retarding heat transfer with a baffle disposed between a container which holds the body of a second molten metal and a furnace assembly with the baffle disposed above and spaced from the layer of insulating material. 
   
   
       19 . A method as set forth in  claim 15  wherein said step of deflecting first portions of the layer of insulating material includes engaging the layer of insulating material with lower surfaces on the support sections and deflecting the first portions of the insulating material under the influence of force transmitted from the lower surfaces on the support sections to the first portions of the layer of insulating material. 
   
   
       20 . A method as set forth in  claim 19  wherein the lower surfaces on the support sections extend parallel to upper surfaces on the support sections and said step of deflecting first portions of the layer of insulating material includes applying force against an upper side of the layer of insulating material with the lower surfaces on the support sections. 
   
   
       21 . A method as set forth in  claim 19  wherein the lower surfaces on the support sections include side surface areas which extend transversely to upper surfaces of the support sections and intersect to provide a lower portion of each of the support sections with downwardly tapering configuration, said step of deflecting portions of the layer of insulating material includes deflecting insulating material in one direction with a first side surface area on the lower portion of one of the support sections and deflecting insulating material in a second direction with a second side surface area on the lower portion of said one of the support sections. 
   
   
       22 . A method as set forth in  claim 15  wherein each of the support sections extends outwardly from a central portion of the support structure so that the space extending between adjacent support sections increases in a direction extending outwardly from the central portion of the support structure. 
   
   
       23 . A method as set forth in  claim 15  wherein the support sections are interconnected to form a ring so that the space extending between the support sections is disposed within the ring. 
   
   
       24 . A method as set forth in  claim 15  wherein the support structure is disposed in a spatial envelope having a polygonal configuration and occupies between five percent (5%) and twenty-five percent (25%) of the area contained within the polygon forming the spatial envelope.