Casting furnace method and apparatus

Abstract

A system for casting comprising a mold for forming molten metal; a support for supporting the mold and transferring heat to and from the mold; and a furnace operable to substantially surround the mold through a preheat cycle, a heat cycle, and a cooling cycle. The furnace preferably moves vertically down to surround the mold for the preheat, heat, and cooling cycles and moves up and away from the mold after the cooling cycle is complete. In an alternative embodiment, the furnace may be replaced with a cooling can just before initiation of the cooling cycle. The support is preferably stationary and provides directional cooling for the mold during the cooling cycle.

1 . A system for casting comprising:
 a mold for forming molten metal;   a support for supporting the mold, the support being operable to transfer heat to and from the mold; and   a furnace operable to substantially surround the mold through a preheat cycle and a heat cycle.   
   
   
       2 . The system as set forth in  claim 1 , wherein the furnace moves vertically. 
   
   
       3 . The system as set forth in  claim 2 , wherein the furnace moves down to surround the mold for the preheat cycle, the heat cycle, and a cooling cycle and moves up and away from the mold after the cooling cycle is complete. 
   
   
       4 . The system as set forth in  claim 1 , wherein the support is substantially stationary, such that the furnace moves toward and away from the support. 
   
   
       5 . The system as set forth in  claim 1 , wherein the support uses resistance heating during both the preheat and heat cycles. 
   
   
       6 . The system as set forth in  claim 1 , wherein the support cools the mold during the cooling cycle using a fluid spray. 
   
   
       7 . The system as set forth in  claim 1 , wherein the support provides directional cooling for the mold during the cooling cycle by receiving cooling medium through passages in the support. 
   
   
       8 . The system as set forth in  claim 1 , wherein the furnace is replaced with a cooling can for a cooling cycle. 
   
   
       9 . The system as set forth in  claim 1 , wherein the furnace uses resistance heating. 
   
   
       10 . The system as set forth in  claim 1 , wherein the support is primarily constructed of a material selected from the group consisting of graphite, ceramic, and silicon carbide. 
   
   
       11 . The system as set forth in  claim 1 , wherein the support includes a ceramic coating. 
   
   
       12 . An apparatus for casting metal in a mold comprising:
 a substantially stationary support for supporting the mold, the support being operable to transfer heat to the mold using resistance heating and transfer heat from the mold by receiving a cooling medium through passages in the support; and   a vertically moving resistance furnace operable to move down to substantially surround the mold through a preheat cycle, a heat cycle, and a cooling cycle, wherein the furnace moves up and away from the mold after the cooling cycle is complete.   
   
   
       13 . A method for casting metal in a mold comprising the steps of:
 placing solid metal ingots in the mold;   placing the mold on a support;   lowering a furnace to surround the mold on the support;   transferring heat from the support and furnace to the mold, thereby melting the metal ingots;   transferring heat from the mold to the support using a cooling system integral to the support; and   raising the furnace away from the mold.   
   
   
       14 . The method as set forth in  claim 13 , wherein the support is substantially stationary, such that the furnace moves toward and away from the support and the furnace moves vertically down to surround the mold for preheat, heat, and cooling cycles and moves up and away from the mold after the cooling cycle is complete. 
   
   
       15 . The method as set forth in  claim 13 , wherein the support uses resistance heating during both preheat and heat cycles. 
   
   
       16 . The method as set forth in  claim 13 , wherein the cooling system comprises a fluid spray. 
   
   
       17 . The method as set forth in  claim 13 , wherein the cooling system comprises a cooling medium passing through passages in the support. 
   
   
       18 . The method as set forth in  claim 13 , further including the step of lowering a cooling can to surround the mold for a cooling cycle. 
   
   
       19 . The method as set forth in  claim 13 , wherein the furnace uses resistance heating. 
   
   
       20 . The method as set forth in  claim 13 , wherein the mold is held stationary during preheat, heat, and cooling cycles.