Metal composite production method

Abstract

A metal composite apparatus and a method to produce the metal composite apparatus is disclosed, including placing a metal skeleton inside a mold, the metal skeleton having a skeleton top surface, a skeleton bottom surface, cutouts, and a central bore having a top end and a bottom end; pouring molten white iron into the mold to substantially encapsulate the metal skeleton forming a single piece cast; protecting the top end and the bottom end of the central bore from contact with the molten white iron; and cooling the single piece cast to form the metal composite apparatus having an apparatus top surface and an apparatus bottom surface.

What is claimed is: 
     
         1 . A method of producing a metal composite apparatus comprising:
 a. placing a metal skeleton comprising metal inside a mold, wherein the metal skeleton comprises a skeleton top surface, a skeleton bottom surface, cutouts, and a central bore having a top end and a bottom end;   b. pouring molten white iron into the mold to substantially encapsulate the metal skeleton forming a single piece cast; wherein the top end and the bottom end of the central bore are protected from contact with the molten white iron; the melting point of the metal of the metal skeleton is equal to or greater than the melting point of the molten white iron; and   c. cooling the single piece cast to form the metal composite apparatus having an apparatus top surface and an apparatus bottom surface.   
     
     
         2 . The method of  claim 1  wherein the metal of the metal skeleton has lower hardness, better machinability and better shock absorption than the white iron in solid form. 
     
     
         3 . The method of  claim 1  wherein the metal of the metal skeleton comprises a metal alloy. 
     
     
         4 . The method of  claim 3  wherein the metal alloy is an alloy steel. 
     
     
         5 . The method of  claim 1  wherein the white iron has superior wear resistance as compared to the metal of the metal skeleton. 
     
     
         6 . The method of  claim 1  wherein the metal skeleton further comprises at least two protrusions extending from the skeleton bottom surface and protruding through the apparatus bottom surface following step c. 
     
     
         7 . The method of  claim 1  wherein the metal skeleton further comprises at least two holes adjacent the central bore, and wherein ceramic rods are placed in the holes and, following step b, extend from below the apparatus bottom surface to above the apparatus top surface; and wherein the ceramic rods are removed from the metal composite apparatus. 
     
     
         8 . A metal composite apparatus comprising white iron substantially encapsulating a metal skeleton comprising metal, a skeleton top surface, a skeleton bottom surface, cutouts, and a central bore; wherein the central bore is not encapsulated with the white iron. 
     
     
         9 . The metal composite apparatus of  claim 8  wherein the metal of the metal skeleton has lower hardness, better machinability and better shock absorption than the white iron in solid form. 
     
     
         10 . The metal composite apparatus of  claim 8  wherein the metal of the metal skeleton comprises a metal alloy. 
     
     
         11 . The metal composite apparatus of  claim 10  wherein the metal alloy is an alloy steel. 
     
     
         12 . The metal composite apparatus of  claim 8  wherein the white iron has superior wear resistance as compared to the metal of the metal skeleton. 
     
     
         13 . The metal composite apparatus of  claim 8  wherein the melting point of the white iron is lower than the melting point of the metal of the metal skeleton. 
     
     
         14 . The metal composite apparatus of  claim 8  further comprising an apparatus top surface and an apparatus bottom surface; wherein the metal skeleton further comprises at least two protrusions extending from the skeleton bottom surface and protruding through the apparatus bottom surface. 
     
     
         15 . The metal composite apparatus of  claim 8  further comprising at least two holes adjacent the central bore and extending from the apparatus bottom surface to the apparatus top surface. 
     
     
         16 . A method of producing a slinger and impeller assembly comprising:
 i. producing a slinger by a method comprising:
 a. placing a metal skeleton inside a mold, wherein the metal skeleton comprises metal, a skeleton top surface, a skeleton bottom surface, cutouts, a metal skeleton central bore having a top end and a bottom end, at least two protrusions extending from the skeleton bottom surface and each having a distal end positioned below the apparatus bottom surface following step c; 
 b. pouring molten white iron into the mold to substantially encapsulate the metal skeleton forming a single piece cast which is substantially circular at its outer edge; wherein the top end and the bottom end of the central bore are protected from contact with the molten white iron; and 
 c. cooling the single piece cast to form the slinger having a slinger top surface and a slinger bottom surface; 
   ii. utilizing an impeller comprising an impeller central bore alignable with the metal skeleton central bore, an impeller bottom surface, and an impeller top surface comprising at least two recesses sized and positioned to receive the distal ends of the at least two protrusions of the metal skeleton;   iii. aligning the metal skeleton central bore with the impeller central bore, positioning the distal ends of the at least two protrusions of the metal skeleton into the at least two recesses of the impeller top surface; and   iv. fastening the impeller to the slinger.   
     
     
         17 . The method of  claim 16  wherein the at least two protrusions are positioned such that a space is created between the slinger bottom surface and the impeller top surface. 
     
     
         18 . The method of  claim 16  wherein the metal skeleton further comprises at least two holes adjacent the metal skeleton central bore, and wherein ceramic rods are placed in the holes and, following step c, extend from below the slinger bottom surface to above the slinger top surface; and wherein the ceramic rods are removed from the slinger. 
     
     
         19 . The method of  claim 18  wherein the removal of the ceramic rods creates at least two breathing holes adjacent the metal skeleton central bore providing a path for air to pass from the space between the slinger bottom surface and the impeller top surface through the breathing holes for escape above the slinger top surface. 
     
     
         20 . The method of  claim 16  wherein the metal skeleton central bore is tapered, wherein the impeller central bore is tapered, and wherein the metal skeleton central bore and the impeller central bore each fit onto a vortex mixer shaft.