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Elliott, SC

Andrew J. Elliott, Westminster, SC US

Patent application numberDescriptionPublished
20100071812UNIDIRECTIONALLY-SOLIDIFICATION PROCESS AND CASTINGS FORMED THEREBY - A process capable of producing large metallic castings having lengths of one hundred centimeters or more and a unidirectional crystal structure substantially free of freckle defects. The process includes pouring a molten metal alloy into a preheated mold within a heating zone, withdrawing the mold from the heating zone, through a heat shield, and into a cooling zone to directionally solidify the molten metal alloy, and then cooling the mold to produce the casting and the unidirectional crystal structure thereof. The heat shield operates as a barrier to thermal radiation between the heating zone and the cooling zone, and the mold is withdrawn at a rate that, in combination with the heat shield, maintains a thermal gradient to solidify the molten metal alloy and form primary dendrite arms having an average spacing therebetween of about 150 to about 500 micrometers.03-25-2010
20100147481METHODS OF MANUFACTURING CASTED ARTICLES, AND SYSTEMS - A method for manufacturing a casted article is presented. The method includes steps of forming a casted article by a liquid metal cooled directional solidification process, removing a metallic material from a surface of the casted article and inspecting the surface of the casted article. The surface of the casted article is inspected for the presence of the metallic material by exposing the surface to a visualization reagent. A system for manufacturing the casted article is also presented.06-17-2010

Andrew John Elliott, Westminster, SC US

Patent application numberDescriptionPublished
20100170654Casting Molds for Use in Directional Solidification Processes and Methods of Making - Casting molds suitable for directional solidification processes using a liquid cooling bath include a graded facecoat structure on a mold body. The graded facecoat structure includes an innermost layer and a delamination layer, wherein the delamination layer fractures upon cooling of the molten metal so as to separate the mold body from the innermost layer, which remains in contact with or in close proximity to the metal being cast. Also disclosed are directional solidification processes.07-08-2010

Andrew John Elliott, Greer, SC US

Patent application numberDescriptionPublished
20080257517MOLD ASSEMBLY FOR USE IN A LIQUID METAL COOLED DIRECTIONAL SOLIDIFICATION FURNACE - A mold assembly for a liquid metal cooled directional solidification furnace having a cooling chamber provided with liquid metal and a heating chamber includes a mold member having a main body portion that defines an interior mold cavity. The mold member is adapted to be positioned in the heating chamber. The mold assembly also includes a chill-plate formed from a material having a thermal diffusivity a 600° K greater than approximately 10 E-6 m2/s, inert to at least one of molten tin and molten aluminum and adapted to be at least partially immersed in the liquid metal. The chill-plate includes a main body portion having a first surface extending to a second surface through an intermediate portion. The chill-plate is adapted to establish a thermal gradient between the mold member and the heating chamber.10-23-2008
20090126893Liquid Metal Directional Casting Process - Processes for directionally casting liquid metal to form an articles can include compressing a seal intermediate a mold chill plate and a mold assembly, wherein the seal circumscribes a shell mold in the mold assembly; filling the shell mold in the mold assembly with molten metal; immersing the mold assembly into a liquid metal cooling bath from a bottom portion to a top portion of the mold assembly; and transmitting heat from the mold assembly to the liquid metal cooling bath to solidify the molten metal from the bottom portion to the top portion of the mold assembly.05-21-2009
20090126894LIQUID METAL DIRECTIONAL CASTING APPARATUS - An apparatus for directionally casting articles generally includes a seal between a mold assembly and chill plate. In one embodiment, the mold assembly includes a skirt laterally extending from at least one shell mold, wherein the skirt includes a channel disposed in a bottom surface that is configured to surround the at least one shell mold. A chill plate fastened to a bottom of the mold assembly and includes a boss having a shape complementary to the channel, wherein the boss of the chill plate is seated within the channel of the mold assembly to define the seal about the at least one shell mold.05-21-2009
20090205799CASTING MOLDS FOR USE IN A DIRECTIONAL SOLIDIFICATION PROCESS AND METHODS OF MAKING08-20-2009
20090314390Alloy Castings Having Protective Layers and Methods of Making the Same - An alloy casting having a protective layer disposed on a surface of the casting is provided. The protective layer is resistant to liquid metal attack, and wherein the protective layer includes an oxide of an element present in the alloy. A method of forming a protective layer on a surface of the alloy casting is also provided. The method includes disposing the alloy in a mold, and oxidizing an element of the alloy to form a protective layer on the surface of the casting.12-24-2009