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1. 发明授权

US06763876B1 Method and apparatus for casting of metal articles using external pressure 有权
标题翻译：使用外部压力铸造金属制品的方法和装置
公开(公告)号：US06763876B1
公开(公告)日：2004-07-20
申请号：US10228935
申请日：2002-08-27
申请人： Raymond J. Donahue , Terrance M. Cleary , Parker A. Stroom
发明人： Raymond J. Donahue , Terrance M. Cleary , Parker A. Stroom
IPC分类号： B22C904
CPC分类号： B22D18/04 , B22C9/046 , B22D21/007 , B22D27/13
摘要： A method for casting of metal articles using external pressure and having particular application to lost foam casting of metal articles. A polymeric foam pattern having a configuration corresponding to an article to be cast is placed in an outer flask and the pattern is connected through a polymeric foam gating system to a pouring cup located at the upper end of the flask. The pouring cup has a volume equal to 5% to 75% of the combined volume of the gating system and the pattern. A finely divided inert material, such as sand, is placed in the flask surrounding the pattern and fills the internal cavities within the pattern. The flask containing the pattern is then positioned in an outer pressure vessel having a removable lid and a molten metal is fed into the pouring cup. The lid on the pressure vessel is closed and an external gaseous pressure is applied to the molten metal in the pouring cup as the molten metal feeds through the gating system to the pattern and progressively decomposes the polymeric foam material. The gaseous products of decomposition passing into the interstices of the sand and the molten metal filling the void created by decomposition of the foam. By applying pressure to the molten metal during filling, the molten metal front is more stable and fewer casting defects arise.
摘要翻译：一种使用外部压力铸造金属制品并且特别适用于金属制品的失去泡沫铸造的方法。将具有对应于待铸造制品的构造的聚合物泡沫图案放置在外部烧瓶中，并且图案通过聚合物泡沫浇口系统连接到位于烧瓶上端的浇注杯。浇注杯的体积等于浇注系统和图案的组合体积的5％至75％。将细碎的惰性材料（例如砂）放置在围绕图案的烧瓶中，并填充图案内的内部空腔。然后将含有图案的烧瓶放置在具有可拆卸盖的外部压力容器中，并将熔融金属进料到浇注杯中。当熔融金属通过浇注系统进料到图案并逐渐分解聚合物泡沫材料时，压力容器上的盖子被关闭并且外部气体压力施加到浇注杯中的熔融金属。分解的气体产物进入砂的空隙和填充由泡沫分解产生的空隙的熔融金属。通过在填充期间对熔融金属施加压力，熔融金属前端更稳定，并且产生更少的铸造缺陷。

2. 发明授权

US06427759B1 Investment cast stainless steel marine propeller 有权
标题翻译：投资不锈钢船用螺旋桨
公开(公告)号：US06427759B1
公开(公告)日：2002-08-06
申请号：US09585136
申请日：2000-06-01
申请人： Richard S. Bauer , Barry L. Riutta , Terrance M. Cleary , Raymond J. Donahue , Kevin R. Anderson
发明人： Richard S. Bauer , Barry L. Riutta , Terrance M. Cleary , Raymond J. Donahue , Kevin R. Anderson
IPC分类号： B22C900
CPC分类号： C22C38/48 , B22C7/02 , B22C9/04 , C22C38/42
摘要： An investment cast stainless steel article, such as a marine propeller, is composed of a stainless steel alloy containing from 14.5 to 15.2% chromium, 5.35% to 6.05% nickel and 1.0% to 1.5% silicon. During the investment casting procedure, the increased silicon in the stainless steel lowers the driving force for the silicon from reacting with the molten metal, thereby reducing casting defects and decreasing the time and labor required for final grinding and polishing of the propeller
摘要翻译：投资不锈钢制品如船用螺旋桨由含有14.5至15.2％铬，5.35％至6.05％镍和1.0％至1.5％硅的不锈钢合金组成。在熔模铸造过程中，不锈钢中增加的硅降低了硅与熔融金属反应的驱动力，从而减少了铸造缺陷并减少了螺旋桨的最终研磨和抛光所需的时间和人力

3. 发明授权

US5290373A Evaporable foam casting system utilizing an aluminum-silicon alloy containing a high magnesium content 失效
标题翻译：使用含有高镁含量的铝硅合金的可蒸发泡沫浇注系统
公开(公告)号：US5290373A
公开(公告)日：1994-03-01
申请号：US52170
申请日：1993-04-23
申请人： Raymond J. Donahue , Terrance M. Cleary , William G. Hesterberg
发明人： Raymond J. Donahue , Terrance M. Cleary , William G. Hesterberg
IPC分类号： B22C9/04 , C22C21/02 , C22F1/043 , C22F1/04
CPC分类号： C22F1/043 , B22C9/046 , C22C21/02
摘要： A method of evaporable foam casting of metal articles, such as engine blocks for internal combustion engines. An evaporable foam pattern having a configuration proportionally identical to the article to be cast is positioned in a mold and a finely divided flowable material, such as sand, surrounds the pattern and fills the internal cavities of the pattern. A molten hypereutectic aluminum-silicon alloy containing 16% to 19.5% by weight of silicon and containing a magnesium content in excess of the magnesium solid solubility limit, is fed into the mold and into contact with the pattern. The heat of the molten metal vaporizes the pattern, with the vapor being trapped within the sand and the molten metal filling the void created by vaporization of the pattern to provide a cast article. The high magnesium content in the alloy produces in the solid state a Mg.sub.2 Si phase in the eutectic and in the molten state an insulating magnesium oxide surface film which decreases the chilling of the molten metal front and prevents the liquid styrene defects resulting from degradation of the polymeric material.
摘要翻译：一种用于内燃机的发动机缸体的金属制品的可蒸发泡沫铸造的方法。具有与要铸造的制品成比例地相同的构造的可蒸发泡沫图案位于模具中，并且细碎的可流动材料（例如砂）围绕图案并填充图案的内部空腔。将含有16重量％至19.5重量％硅并含有镁含量超过镁固溶度极限的熔融过共晶铝硅合金进料到模具中并与图案接触。熔融金属的热量蒸发图案，其中蒸汽被捕获在砂中，并且熔融金属填充由图案的蒸发产生的空隙以提供铸造制品。合金中的高镁含量在固态中产生在共晶中和在熔融状态下的Mg2Si相，其中绝缘的氧化镁表面膜减少了熔融金属前沿的冷却，并且防止由聚合物降解引起的液体苯乙烯缺陷材料。

4. 发明授权

US07347905B1 Aluminum-silicon alloy having reduced microporosity and method for casting the same 有权
标题翻译：具有降低的微孔的铝硅合金及其铸造方法
公开(公告)号：US07347905B1
公开(公告)日：2008-03-25
申请号：US11174764
申请日：2005-07-05
申请人： Raymond J. Donahue , Terrance M. Cleary , Kevin R. Anderson
发明人： Raymond J. Donahue , Terrance M. Cleary , Kevin R. Anderson
IPC分类号： C22C21/04
CPC分类号： C22C21/04 , C22C21/02
摘要： An aluminum-silicon lost foam casting alloy having reduced microporosity and a method for casting the same is herein disclosed. A preferred lost foam cast alloy consists essentially of 6 to 12% by weight silicon and preferably 9.0 to 9.5% by weight silicon, 0.035-0.30% strontium, 0.40% maximum iron, 0.45% maximum copper, 0.49% maximum manganese, 0.60% maximum magnesium, 3.0% maximum zinc, and the balance aluminum. Most preferably, the lost foam alloy is free from iron, titanium and boron. However, such elements may exist at trace levels. Most preferably, the alloy is lost foam cast with the process that applies at least 10 atmospheres of pressure during solidification. However, the range may be 5 to 60 atmospheres. The strontium addition is greater than 0.005% by weight and most preferably greater than 0.05% by weight. In accordance with the present disclosure, alloys having substantially decreased tensile liquid failure defects and substantially decreased surface puncture defects in comparison to conventional lost foam cast aluminum silicon alloys are obtained. Further, hydrogen porosity formation is substantially completely suppressed and surface porosity defects are substantially decreased in comparison to conventional lost foam silicon alloys when casting lost foam cast alloys in accordance with the claims of the instant disclosure. The instant disclosure further discloses aluminum silicon alloys that may be utilized in both the lost foam with pressure and the die casting processes.
摘要翻译：本文公开了具有降低的微孔性的铝硅损失泡沫铸造合金及其铸造方法。优选的失去泡沫铸造合金基本上由6-12重量％的硅组成，优选的是硅，9.0- 9.5重量％的硅，0.035-0.30％的锶，0.40％的最大铁，最大铜的0.45％，最大锰的0.49％，最大的0.60％镁，3.0％最大锌，余量为铝。最优选地，失去的泡沫合金不含铁，钛和硼。然而，这些元素可以以痕量水平存在。最优选的是，合金是在熔化过程中至少施加至少10个大气压的过程而失去的泡沫铸造。然而，该范围可以是5至60个大气压。锶添加量大于0.005重量％，最优选大于0.05重量％。根据本公开，获得了与常规的失去泡沫铸造铝硅合金相比，具有显着降低的拉伸液体破坏缺陷和显着降低的表面穿孔缺陷的合金。此外，根据本公开的权利要求，当铸造失去泡沫的铸造合金时，与常规的失去泡沫硅合金相比，基本上完全抑制了氢气孔隙形成，并且表面孔隙率缺陷显着降低。本公开进一步公开了可以用于压力失去的泡沫和压铸工艺中的铝硅合金。

5. 发明授权

US07100669B1 Aluminum-silicon casting alloy having refined primary silicon due to pressure 失效
标题翻译：铝硅铸造合金由于压力而具有精炼的一次硅
公开(公告)号：US07100669B1
公开(公告)日：2006-09-05
申请号：US10409798
申请日：2003-04-09
申请人： Raymond J. Donahue , Terrance M. Cleary
发明人： Raymond J. Donahue , Terrance M. Cleary
IPC分类号： B22C9/04 , B22D27/13
CPC分类号： B22C9/04 , B22D21/007 , B22D27/13
摘要： Provided herein is a method for refining primary silicon present in a hypereutectic aluminum silicon alloy. The method contemplates the controlled application of pressure to refine the primary silicon during the casting of articles. The application of pressure decreases the primary silicon particle size to improve the machinability and wear resistance of the final cast articles.
摘要翻译：本文提供了一种用于精炼存在于过共晶铝硅合金中的一次硅的方法。该方法考虑了在铸造制品期间可控制地施加压力以细化一次硅。施加压力降低了初级硅颗粒尺寸，以改善最终铸造制品的机械加工性和耐磨性。

6. 发明授权

US06923935B1 Hypoeutectic aluminum-silicon alloy having reduced microporosity 有权
标题翻译：低共晶铝硅合金具有降低的微孔
公开(公告)号：US06923935B1
公开(公告)日：2005-08-02
申请号：US10429098
申请日：2003-05-02
申请人： Raymond J. Donahue , Terrance M. Cleary , Kevin R. Anderson
发明人： Raymond J. Donahue , Terrance M. Cleary , Kevin R. Anderson
IPC分类号： C22C21/02 , C22C21/04
CPC分类号： C22C21/04 , C22C21/02
摘要： A hypoeutectic aluminum silicon casting alloy having a refined primary silicon particle size and a modified iron morphology. The alloy includes 10 to 11.5% by weight silicon, 0.10 to 0.70% by weight magnesium and also contains 0.05 to 0.07% by weight strontium. On cooling from the solution temperature, the strontium serves to modify the silicon eutectic structure as well as create an iron phase morphology change. Such changes facilitate feeding through the aluminum interdendritic matrix. This, in turn, creates a finished die cast product with extremely low levels of microporosity defects. The alloy may be used to cast engine blocks for marine outboard and stern drive motors. Furthermore, when the magnesium levels are adjusted to approximately 0.10 to 0.20% by weight magnesium, propellers having a highly advantageous ductility may be obtained.
摘要翻译：具有精制一次硅粒径和改性铁形态的亚共晶铝硅铸造合金。该合金包括10〜11.5重量％的硅，0.10〜0.70重量％的镁，还含有0.05〜0.07重量％的锶。在从溶液温度冷却时，锶用于改变硅共晶结构以及产生铁相形态变化。这种变化有助于通过铝树枝状间质基体进料。这又产生了具有极低水平的微孔缺陷的成品压铸产品。该合金可用于铸造船用舷外驱动电机的发动机缸体。此外，当将镁水平调节至约0.10至0.20重量％的镁时，可以获得具有高有利延展性的螺旋桨。

7. 发明授权

US5355931A Method of expendable pattern casting using sand with specific thermal properties 失效
标题翻译：使用具有特定热性能的沙子的消耗模式铸造方法
公开(公告)号：US5355931A
公开(公告)日：1994-10-18
申请号：US119035
申请日：1993-09-09
申请人： Raymond J. Donahue , Terrance M. Cleary , William G. Hesterberg , Terry C. Holmgren
发明人： Raymond J. Donahue , Terrance M. Cleary , William G. Hesterberg , Terry C. Holmgren
IPC分类号： B22D21/04 , B22C1/00 , B22C1/08 , B22C9/04 , B22C9/22 , B22C7/02
CPC分类号： B22C1/00 , B22C1/08 , B22C9/04 , B22C9/046
摘要： A method of producing dimensionally predictable metal castings utilizing an expendable polymeric foam pattern along with unbonded sand having specific thermal properties. The pattern, formed of a material such as polystyrene, has a configuration corresponding to that of the article to be cast. The pattern is placed with an outer flask and unbonded sand surrounds the pattern as well as filling the cavities in the pattern. The sand has a linear expansion of less than 1% from 0.degree. C. to 1600.degree. C., a heat diffusivity greater than 1500 J/m.sup.2 /.degree.K/S1/2, an AFS grain fineness number of 25 to 33, and an AFS base permeability number of 450 to 500. A molten metal, such as an aluminum alloy or a ferrous alloy, is fed into the mold in contact with the pattern causing the pattern to vaporize with the vapor being entrapped within the interstices of the sand while the molten metal fills the space initially occupied by the foam pattern to produce a cast article. The physical properties of the sand enable articles to be cast having more precise and predictable tolerances.
摘要翻译：使用消耗性聚合物泡沫图案以及具有特定热特性的未粘合砂制造尺寸可预测的金属铸件的方法。由诸如聚苯乙烯的材料形成的图案具有对应于待铸造制品的构型。将图案放置在外部烧瓶中，并且未粘合的砂围绕图案以及以图案填充空腔。砂从0℃到1600℃的线膨胀小于1％，热扩散系数大于1500J / m 2 /°K / S1 / 2，AFS颗粒细度为25〜33， AFS基础渗透性数值为450至500.将诸如铝合金或铁合金的熔融金属与图案接触地进料到模具中，导致图案蒸发，蒸汽被捕获在砂的空隙内而熔融金属填充最初由泡沫图案占据的空间以产生铸造制品。砂的物理性能使得能够铸造的制品具有更精确和可预测的公差。

8. 发明授权

US5165464A Method of casting hypereutectic aluminum-silicon alloys using a salt core 失效
标题翻译：使用盐芯铸造过共晶铝硅合金的方法
公开(公告)号：US5165464A
公开(公告)日：1992-11-24
申请号：US767260
申请日：1991-09-27
申请人： Raymond J. Donahue , William G. Hesterberg , Terrance M. Cleary , Lawrence I. Toriello
发明人： Raymond J. Donahue , William G. Hesterberg , Terrance M. Cleary , Lawrence I. Toriello
IPC分类号： B22C9/10 , B22D17/24 , B22D21/00 , B22D29/00 , C22C1/05
CPC分类号： B22D17/24 , B22D21/007 , B22D29/002
摘要： A method of high pressure casting of hypereutectic aluminum-silicon alloys using a salt core to form wear resistant articles, such as engine blocks. To produce an engine block, one or more solid salt cores are positioned within a metal mold with the space between the cores and the mold defining a die cavity. A molten hypereutectic aluminum-silicon alloy containing more than 12% silicon is fed into the die cavity and on solidification of the molten alloy, precipitated silicon crystals are formed, which are distributed throughout the wall thickness of the cast part and also on the surface bordering the salt cores which constitute the cylinder bores in the cast block. The salt cores are subsequently removed from the cast block by contact with a solvent such as water.
摘要翻译：使用盐芯高过渡共晶铝硅合金的高压铸造方法来形成诸如发动机块的耐磨制品。为了产生发动机缸体，一个或多个固体盐芯位于金属模具内，其中芯和模具之间的空间限定模腔。将含有12％以上硅的熔融过共晶铝硅合金进料到模腔中，并在熔融合金凝固时形成析出的硅晶体，其分布在铸件的壁厚以及边界面构成缸体的盐芯在铸块中钻孔。盐芯随后通过与溶剂如水接触而从铸块中除去。

9. 发明授权

US4875985A Method and appparatus for producing titanium 失效
标题翻译：生产钛的方法和设备
公开(公告)号：US4875985A
公开(公告)日：1989-10-24
申请号：US258035
申请日：1988-10-14
申请人： Raymond J. Donahue , William G. Hesterberg , Terrance M. Cleary
发明人： Raymond J. Donahue , William G. Hesterberg , Terrance M. Cleary
IPC分类号： C22B4/00 , C22B9/22 , C22B34/12
CPC分类号： C22B34/1263 , C22B4/005 , C22B9/226
摘要： A method of producing titanium. A quantity of titanium is heated in a crucible to provide a melt, and a layer of slag, containing an ionizable titanium compound, such as titanium dioxide, along with ionizable slag constituents, is disposed on the top of the melt. The slag is then heated to a molten state by direct current plasma arc heating with the melt being anodic. After the slag is molten, the polarity of the plasma arc heating is reversed so that the melt is cathodic, causing the slag to act as an electron transfer layer so that the titanium dioxide of the slag is reduced to titanium and any dissolved oxygen in the melt is converted to an ionic species of oxygen at the interface between the slag and the melt. The resulting liquid titanium is combined with the melt, while the ionic species of oxygen is carried upwardly through the slag and released from the slag layer by an oxidation process. Additional quantities of titanium dioxide can be added to the slag to continually convert the titanium dioxide to titanium under the reverse polarity plasma arc heating.
摘要翻译：钛的制造方法。在坩埚中加热一定数量的钛以提供熔体，并且在熔体的顶部设置包含可电离的钛化合物（例如二氧化钛）以及可离子化的炉渣成分的炉渣层。然后通过直接等离子体电弧加热将炉渣加热至熔融状态，熔体是阳极的。炉渣熔化后，等离子体电弧加热的极性反转，使得熔体呈阴极，从而使炉渣作为电子转移层，从而将炉渣的二氧化钛还原为钛，并将其中的溶解氧熔体在炉渣和熔体之间的界面转化为氧离子。所得到的液体钛与熔体结合，而氧的离子物质向上运送通过炉渣并通过氧化过程从渣层释放。可以向渣中加入额外量的二氧化钛，以在反极性等离子体电弧加热下将二氧化钛连续地转化为钛。

10. 发明授权

US07666353B2 Aluminum-silicon alloy having reduced microporosity 有权
标题翻译：具有降低微孔的铝硅合金
公开(公告)号：US07666353B2
公开(公告)日：2010-02-23
申请号：US11042252
申请日：2005-01-25
申请人： Raymond J. Donahue , Terrance M. Cleary , Kevin R. Anderson
发明人： Raymond J. Donahue , Terrance M. Cleary , Kevin R. Anderson
IPC分类号： C22C21/04
CPC分类号： C22C21/04 , C22C21/02
摘要： An aluminum silicon die cast alloy having a very low iron content and relatively high strontium content that prevents soldering to dies into die casting process. The alloys of the present invention also have a modified eutectic silicon and modified iron morphology, when iron is present, resulting in low microporosity and high impact properties. The alloy comprises 6-22% by weight silicon, 0.05 to 0.20% by weight strontium and the balance aluminum. Preferably, the alloy of the present invention contains in weight percent: 6-20% silicon, 0.05-0.10% strontium, 0.40% maximum iron and most preferably 0.20% maximum iron, 4.5% maximum copper, 0.50% maximum manganese, 0.60% maximum magnesium, 3.0% maximum zinc, balance aluminum. On cooling from the solution temperature, the strontium serves to modify the eutectic silicon structure as well as create an iron phase morphology change if iron is present, facilitating feeding through the aluminum interdendritic matrix. This, in turn, creates a finished die cast product with extremely low levels of microporosity defects. The strontium content also appears to create a non-wetting monolayer of strontium atoms on the surface of a molten casting, preventing die soldering, even at very low iron contents. The alloy may be used to cast any type of object and is particularly suited for casting outboard marine propellers, driveshaft housings, gear case housings, Gimbel rings and engine blocks.
摘要翻译：铝硅压铸合金，具有非常低的铁含量和相对较高的锶含量，防止模具焊接到压铸过程中。当存在铁时，本发明的合金还具有改性的共晶硅和改性的铁形态，导致低微孔性和高冲击性。该合金包含6-22重量％的硅，0.05-0.20重量％的锶和余量的铝。优选地，本发明的合金优选含有6-20％硅，0.05-0.10％锶，0.40％最大铁，最优选0.20％最大铁，4.5％最大铜，最大锰0.50％，最大0.60％镁，3.0％最大锌，余量铝。在从溶液温度冷却时，锶用于改变共晶硅结构，并且如果存在铁，则产生铁相形态变化，促进通过铝树枝状间质基质进料。这又产生了具有极低水平的微孔缺陷的成品压铸产品。锶含量也似乎在熔融铸件的表面上产生锶原子的非润湿单层，即使在非常低的铁含量下也能防止模具焊接。该合金可用于铸造任何类型的物体，特别适用于铸造船外螺旋桨，传动轴壳体，齿轮箱壳体，Gimbel环和发动机缸体。

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