Rapid localized directional solidification of liquid or semi-solid material contained by media mold

Abstract

An arrangement for forcing rapid localized directional solidification, or global homogenous accelerated solidification of a liquid or semi-solid parent material, which is contained by a media mold that possesses porous properties. The process produces solidified matrix structures and cast properties in the parent material otherwise not possible through conventional solidification methods under ambient conditions. The process is capable of enhancing ordinary production cycles by reducing the overall cycle time required to produce a normally solidified material in a porous media mold. Gas is introduced into the mold media through a manifold or series of manifolds transmitting the gas to spray nozzles and further controlling the physical and mechanical properties of the gas such that the gas permeates through the mold media contacting the liquid or semi solid-parent material and effectively causing rapid solidification of the parent material, primarily as a result of the temperature differential and heat transfer between the gas and the parent material.

1 . A method of rapidly localized and directional solidifying a liquid or semi-solid parent material in a media mold, comprising:
 introducing onto the parent material in a controlled and localized manner a gas having a temperature that is different from that of the parent material, the gas being introduced in such a manner to locally solidify the parent material in a manner and to a degree that certain microstructual constituents will not form.   
   
   
       2 . A method of rapidly localized and directional solidifying a liquid or semi-solid parent material in a media mold, comprising:
 introducing onto the parent material in a controlled localized manner a gas having a temperature that is different from the parent material, the gas being introduced in such a manner to locally solidify the parent material in a manner and to a degree that certain microstructual constituents can be made to form in a controlled manner thereby causing the resultant physical and mechanical properties of the parent material to change in an advantageous manner.   
   
   
       3 . A method of rapidly localized and directional solidifying a liquid or semi-solid parent material in a media mold, comprising:
 introducing onto the parent material in a controlled localized manner a gas having a temperature that is different from the parent material, the gas being introduced in such a manner to locally solidify the parent material in a manner that decreases the time required to solidify a parent material.   
   
   
       4 . A method of rapidly localized and directional solidifying a liquid or semi-solid parent material in a media mold, comprising:
 cooling a predetermined portion of the parent material.   
   
   
       5 . A method according to  claim 4  wherein the cooling step comprises forcing gas onto a localized portion of the parent material. 
   
   
       6 . A method according to  claim 4  further comprising:
 introducing the gas through one or more nozzles in a controlled and localized manner.   
   
   
       7 . A method according to  claim 4  wherein the step of cooling comprises varying a cooling rate of the parent material by introducing gas thereto and varying contact time of the gas with the parent material and controlling its temperature to cause a variable range of properties to be developed throughout the base material structure. 
   
   
       8 . A lost foam casting process, comprising:
 providing an empty molding flask;   positioning a foam cluster about a gas manifold   filling the flask with mold media and compacting the mold;   filling the mold with molten parent material; and   carrying out a gassing sequence in which gas is caused to permeate through the mold media contacting molten metal and effectively forcing a solidification rate or rates which inherently change the structure of the solidified parent material and therefore the resultant properties of the material/metal.   
   
   
       9 . A casting arrangement, comprising:
 a mold made from a porous material;   a gas manifold for supplying gas to the mold during a casting process; and   nozzles for causing gas from the manifold to be dispersed in a localized manner so as to affect portions of the mold during a molding process.   
   
   
       10 . A casting arrangement according to  claim 9  wherein the gas manifold supplies gas from above the mold. 
   
   
       11 . A casting arrangement according to  claim 9  wherein the gas manifold supplies gas from below the mold. 
   
   
       12 . A casting arrangement according to  claim 9  wherein the gas manifold supplies gas from the side of the mold. 
   
   
       13 . A lost foam gas quench process, comprising:
 preparing a mold media of an unbonded free flowing substance;   staging the mold media in a storage hopper situated above a molding flask;   preparing a mold;   preparing a foam cluster including a foam pattern, down sprue and gating system;   placing the foam cluster into the molding flask and positioning it about a gas spray manifold using structures that permit repeatable placement mold after mold;   applying energy to the molding flask by an external source;   releasing the staged media from the hopper and allowing it to rain into the flask at a desired rate, whereby as the flask fills with mold media energy applied to the flask causes the media to compact and fully contain and maintain the shape of the casting cluster;   preparing casting material;   selecting a metal alloy desired and making elemental adjustments to the alloy chemistry during melting to achieve the final desired composition accomplish preparing casting material;   filling the mold with the casting material previously prepared; and   releasing gas into the spray manifold and allowing it to flow into the mold through nozzles;   
   
   
       14 . A lost foam gas quench process according to  claim 13  further comprising:
 initializing the gas quenching process upon mold filling.   
   
   
       15 . A lost foam gas quench process according to  claim 13  further comprising:
 initializing the gas quenching process after mold filling has been completed.   
   
   
       16 . A lost foam gas quench process according to  claim 13  further comprising:
 initializing the gas quenching process and allowing it to continue for accelerated mold cooling after casting solidification and desired cast microstructures are completed.   
   
   
       17 . A lost foam gas quench process according to  claim 13  wherein upon contact with the molten parent material the gas medium produces cooling in the parent material at a rate much above (or increased to) normal conventional cooling. 
   
   
       18 . A lost foam gas quench process according to  claim 13  further comprising cooling naturally over a predetermined period of time. 
   
   
       19 . A lost foam gas quench process according to  claim 13  further comprising continuing gas flow globally throughout the mold to induce further cooling. 
   
   
       20 . A lost foam gas quench process according to  claim 13  further comprising separating the mold and cast product. 
   
   
       21 . A lost foam gas quench process according to  claim 13  wherein gas quenching is started after the metal filling process is complete and is continued until the metal is completely solidified. 
   
   
       22 . A lost foam gas quench process according to  claim 13  wherein gas quenching is started during the process of filling the mold with metal and is allowed to continue until the metal is completely solidified and further until some mold super cooling has taken place.