Method for casting moulded pieces

Abstract

There is provided a method for casting molded pieces comprising production of a casting mold comprising a core of molding material, forming a complete core packet positioning the core packet in a support mold with a separation to the core packet back-filling the space between the core packet and the support mold with a free-flowing bulk material, casting the metal melt into the casting mold, opening or removing the support mold after the solidification of the melt, removing at least the majority of the bulk material and the thermal insulation of the remaining core packet with the cast molded piece therein.

1 - 25 . (canceled) 
   
   
       26 . A method for casting molded pieces, comprising:
 preparing the casting mold consisting of cores of molding material which combine to form a core packet;   positioning the core packet in a support mold which is set apart from the core packet;   back-filling the space between the core packet and the support mold with a free-flowing bulk material;   casting metal melt into the casting mold;   opening and removing the support mold once the melt has solidified;   removing at least the majority of the bulk material; and   repeated thermal insulation of the core packet with the cast molded piece located therein.   
   
   
       27 . The method as claimed in  claim 26  wherein said positioning step comprises positioning the core packet on a thermally insulating base as part of the support mold. 
   
   
       28 . The method as claimed in  claim 27  further comprising adding thermally insulating walls and a thermally insulating lid part to the thermally insulating base to form the support mold. 
   
   
       29 . The method as claimed in  claim 28  wherein said opening step comprises removing the thermally insulating lid part and the thermally insulating walls. 
   
   
       30 . The method as claimed in  claim 26  wherein said repeating step comprises providing a thermally insulating hood and a thermally insulating base and placing the thermally insulating hood on the thermally insulating base around the core packet with the molded piece located therein. 
   
   
       31 . The method as claimed in  claim 30  wherein the thermally insulating hood is configured in one piece. 
   
   
       32 . The method as claimed in claim  1  wherein the bulk material is substantially the same material as that used to produce the cores. 
   
   
       33 . The method as claimed in  claim 32  wherein the bulk material and the cores are substantially without additives. 
   
   
       34 . The method as claimed in claim  1  wherein the bulk material has at least one of substantially the same grain size as the molding material or a grain size differing therefrom. 
   
   
       35 . The method as claimed claim  1  wherein the bulk material used is dry sand without additives. 
   
   
       36 . The method as claimed in claim  1  wherein the bulk material used is quartz sand. 
   
   
       37 . The method as claimed in claim  1  wherein said back-filling step comprises pouring the bulk material in to obtain a bulk density. 
   
   
       38 . The method as claimed in claim  1  wherein said back-filling step comprises blowing in the bulk material. 
   
   
       39 . The method as claimed in claim  1  wherein said back-filling step further comprises post-compacting the bulk material using compressed air for the purpose of further compaction. 
   
   
       40 . The method as claimed in claim  1  wherein said back-filling step further comprises post-compacting the bulk material using vibration for the purpose of further compaction. 
   
   
       41 . The method as claimed in  claim 40  wherein the vibration is ultrasonically induced. 
   
   
       42 . The method as claimed wherein said back-filling step further comprises mechanically post-compacted for the purpose of further compaction. 
   
   
       43 . The method as claimed in claim  1  further comprising:
 using the support mold to at least one of thermally insulate the casting mold before and after said casting step;   providing a thermally insulating hood and a thermally insulating base; and   placing the thermally insulating hood on the thermally insulating base with the support mold and casting mold being contained within the thermally insulating hood to thereby use the process heat within the support mold and casting mold for the controlled treatment of at least one of the casting molded piece and the cast mold.   
   
   
       44 . The method as claimed in  claim 43  wherein molding material comprises at least one of an organic and inorganic binder and wherein the process heat serves to burn at least one of the organic or inorganic binder in the molding material. 
   
   
       45 . The method as claimed in  claim 43  wherein the process heat is used for the thermal treatment of the cast molded piece. 
   
   
       46 . The method as claimed in claim  1  further comprising cooling at least one of the cast molded piece or the casting mold and the cast molded piece in a regulated manner. 
   
   
       47 . The method as claimed in  claim 43  further comprising removing gas from at least one of the interior of the casting mold or the thermally insulating hood following the placing step. 
   
   
       48 . The method as claimed in  claim 44  further comprising:
 retaining the gas which forms during the burning of the binder within the thermal insulating hood; and   thereafter, drawing off the gas.   
   
   
       49 . The method as claimed in  claim 43  further comprising supplying additional heat into the thermally insulating hood. 
   
   
       50 . The method as claimed claim  1  wherein at least one of the cores is hollow so as to have a reduced mass.