Displacement-pressure regulator for a casting system

Abstract

A casting system includes a first mold, a second mold, the first mold and the second mold being configured to receive molten metal, the first mold and the second mold exerting pressure on the molten metal to form a mechanical component as the molten metal cools, and a sensor that measures the pressure exerted on the molten metal to provide feedback information to regulate the pressure exerted on the molten metal.

1 . A casting system comprising:
 a first mold;   a second mold, the first mold and the second mold being configured to receive molten metal, the first mold and the second mold exerting pressure on the molten metal to form a mechanical component as the molten metal cools; and   a sensor that measures the pressure exerted on the molten metal to provide feedback information to regulate the pressure exerted on the molten metal.   
     
     
         2 . The system of  claim 1  further comprising a pressure punch that receives the feedback information, the pressure punch varying the exerted pressure on the molten metal. 
     
     
         3 . The system of  claim 2  wherein the exerted pressure is varied according to a desired time-pressure profile. 
     
     
         4 . The system of  claim 1  wherein the sensor is a hydraulic pressure sensor. 
     
     
         5 . The system of  claim 1  wherein the sensor is a stack of Belleville washers. 
     
     
         6 . The system of  claim 1  wherein mold regions around pressure sensors are thermally insulated or externally heated to maintain molten metal in them, the molten metal in pressure repositories being the last regions to solidify so they can sense pressure and act as pressurized kinetic risers from the sensor, and wherein a change in a casting program sequence causes the sensor to initiate pressure instead of sensing pressure. 
     
     
         7 . The system of  claim 1  wherein the sensor is part of a displacement-pressure regulator that provides pressure measurement and feedback control for repository of any excess metal not consumed during compensation of the metal shrinkage during transition from liquid to solid phase transformation, the repositories being passive or kinetic risers to assist in feeding metal shrinkage. 
     
     
         8 . The system of  claim 1  further comprising a plurality of slides positioned within the first mold and the second mold, the positioning of the plurality of slides exerting the direct pressure on the molten metal. 
     
     
         9 . The system of  claim 8  wherein the plurality of slides is four slides. 
     
     
         10 . The casting system of  claim 9  wherein each slide is an insert that reciprocates along a respective channel. 
     
     
         11 . An apparatus to form a mechanical component comprising:
 a first mold;   a second mold, the first mold and the second mold being configured to receive molten metal, the first mold and the second mold exerting pressure on the molten metal to form a mechanical component as the molten metal cools; and   a feedback mechanism that measures the exerted pressure and varies the exerted pressure to a desired time-pressure profile.   
     
     
         12 . The apparatus of  claim 11  wherein the feedback mechanism includes a sensor that measures the exerted pressure. 
     
     
         13 . The apparatus of  claim 12  wherein the feedback mechanism includes a pressure punch that receives feedback information from the sensor, the pressure punch varying the exerted pressure on the molten metal. 
     
     
         14 . The apparatus of  claim 12  wherein the sensor is a hydraulic pressure sensor. 
     
     
         15 . The apparatus of  claim 12  wherein the sensor is a stack of Belleville washers. 
     
     
         16 . The apparatus of  claim 11  further comprising a plurality of slides positioned within the first mold and the second mold, the positioning of the plurality of slides exerting the direct pressure on the molten metal. 
     
     
         17 . The apparatus of  claim 16  wherein the plurality of slides is four slides. 
     
     
         18 . The apparatus of  claim 17  wherein each slide is an insert that reciprocates along a respective channel. 
     
     
         19 . A method to control a casting process to form a mechanical component, the method comprising:
 pouring molten metal into an interior cavity defined by a first mold and a second mold;   exerting pressure on the molten metal to form a mechanical component; and   measuring the exerted pressure and regulating the exerted pressure according to a desired time-pressure profile.   
     
     
         20 . The method of  claim 19  wherein measuring and regulating the exerted pressure includes measuring and regulating with a hydraulic pressure sensor. 
     
     
         21 . The method of  claim 19  wherein measuring and regulating the exerted pressure includes measuring and regulating with a stack of Belleville washers. 
     
     
         22 . The method of  claim 19  wherein exerting pressure includes exerting pressure with a plurality of slides positioned within the first mold and the second mold.