USOO7500509B2

(12) United States Patent (10) Patent No.: US 7,500,509 B2

POWell et al. (45) Date of Patent: Mar. 10, 2009
(54) FEEDER ELEMENT FOR METAL CASTING (56) References Cited
(75) Inventors: Colin Powell, Birmingham (GB); Jan U.S. PATENT DOCUMENTS
Sallstrom, Gunnarskog (SE); Jan Eric 2004/0050526 A1 3/2004 Skerdi et al. ................ 164/359
Pehrsson, Ed (SE)
(73) Assignee: Foseco International Limited, FOREIGN PATENT DOCUMENTS
Tamworth, Staffs (GB) DE 3252637 A1 1, 1987
DE 295 13 017 U1 1, 1996
(*) Notice: Subject to any disclaimer, the term of this DE 1964.2838 A1 7/1997
patent is extended or adjusted under 35 DE 201 12425 U 1 11, 2001
U.S.C. 154(b) by 649 days. DE 20115 140 U 1 3, 2002
DE 20 2004 OO9367 U1 9, 2004
(21) Appl. No.: 10/521,438 EP 1 184 104 A1 3, 2002
JP 49-118620 11, 1974
(22) PCT Filed: Oct. 21, 2004
(86). PCT No.: PCT/GB2OO4/OO4451
* cited by examiner
S371 (c)(1), Primary Examiner Kuang Lin
(2), (4) Date: Jan. 14, 2005 (74) Attorney, Agent, or Firm Nixon & Vanderhye
(87) PCT Pub. No.: WO2005/051568 (57) ABSTRACT
PCT Pub. Date: Jun. 9, 2005
The present invention relates to a feeder element (10) for use
(65) Prior Publication Data in metal casting. The feeder element (10) (which serves the
function of a breaker core) has a first end (16) for mounting on
US 2005/0236132 A1 Oct. 27, 2005 a mould plate (24), an opposite second end (18) for receiving
(30) Foreign Application Priority Data a feeder sleeve (20) and a bore (14) between the first and
second ends (16,18) defined by a sidewall (12). The feeder
Oct. 28, 2003 (GB) ................................. O325.134.5 element (10) is compressible in use whereby to reduce the
(51) Int. Cl. distance between said first and second ends (16,18).
B22C 9/08 (2006.01)
(52) U.S. Cl. ....................................... 164/359; 164/360 The invention also relates to a breaker core/feeder sleeve
(58) Field of Classification Search ................. 164/359, assembly (10.20).
164/360
See application file for complete search history. 22 Claims, 10 Drawing Sheets

1
U.S. Patent Mar. 10, 2009 Sheet 1 of 10 US 7,500,509 B2

Figure 1

16

18
12b

D 12a

Figure 2
U.S. Patent Mar. 10, 2009 Sheet 2 of 10 US 7,500,509 B2
U.S. Patent Mar. 10, 2009 Sheet 3 of 10 US 7,500,509 B2

20a

20a

24
U.S. Patent Mar. 10, 2009 Sheet 4 of 10 US 7,500,509 B2

Figure 7

12a

32a

Figure 7A 32a Figure 7B

U.S. Patent Mar. 10, 2009 Sheet 5 of 10 US 7,500,509 B2

F
-.
H
F - 40
12a
Figure 9 42

12a

42a

s -a

Figure 10

Figure 11 56
U.S. Patent Mar. 10, 2009 Sheet 6 of 10 US 7,500,509 B2

64

66
/
N
<-- 60

Figure 12 - Figure 13

Figure 14 Figure 15
U.S. Patent Mar. 10, 2009 Sheet 7 of 10 US 7,500,509 B2

8O

82
84

Figure 16

Figure 17 Figure 18
U.S. Patent Mar. 10, 2009 Sheet 8 of 10 US 7,500,509 B2

Figure 19 Figure 20
U.S. Patent Mar. 10, 2009 Sheet 9 of 10 US 7,500,509 B2

4000

3000

2000

1000

-1000
Displacement (mm)

Figure 21

Oinitial crush strength (point A)

Minimum crush strength (point B)
Maximum crush strength (point C)

Angle (deg)

Figure 22
U.S. Patent Mar. 10, 2009 Sheet 10 of 10 US 7,500,509 B2

Force N
Comparison of crush strength at different metal thicknesses
4000
3600
32OO
2800
2400
2000
600
2OO
800
400

O.O 2.5 5.O 75 10.O. 12.5 15.O. 17.5 200 22.5 25.0
Extension mrn
 US 7,500,509 B2
1. 2
FEEDERELEMENT FOR METAL CASTING Moulding sand can be classified into two main categories.
Chemical bonded (based on either organic or inorganic bind
This application is the U.S. National Phase of International ers) or clay-bonded. Chemically bonded moulding binders
Application PCT/GB04/004451 filed 21 Oct. 2004, which are typically self-hardening systems where a binder and a
designated the U.S. PCT/GB04/004.451 claims priority to chemical hardener are mixed with the sand and the binder and
British Application No. 0325134.5 filed 28 Oct. 2003. The hardener start to react immediately, but sufficiently slowly
entire content of these applications are incorporated herein by enough to allow the sand to be shaped around the pattern plate
reference. and then allowed to harden enough for removal and casting.
The present invention relates to an improved feeder ele Clay-bonded moulding uses clay and water as the binder
ment for use in metal casting operations utilising casting 10
moulds, especially but not exclusively in high-pressure sand and can be used in the 'green” or undried State and is com
moulding systems. monly referred to as greensand. Greensand mixtures do not
flow readily or move easily under compression forces alone
BACKGROUND OF THE INVENTION and therefore to compact the greensand around the pattern
15 and give the mould sufficient strength properties as detailed
In a typical casting process, molten metal is poured into a previously, a variety of combinations of jolting, vibrating,
pre-formed mould cavity which defines the shape of the cast Squeezing and ramming are applied to produce uniform
ing. However, as the metal solidifies it shrinks, resulting in strength moulds at high productivity. The sand is typically
shrinkage cavities which in turn result in unacceptable imper compressed (compacted) at high pressure, usually using a
fections in the final casting. This is a well known problem in hydraulic ram (the process being referred to as “ramming
the casting industry and is addressed by the use of feeder up'). With increasing casting complexity and productivity
sleeves or risers which are integrated into the mould during requirements, there is a need for more dimensionally stable
mould formation. Each feeder sleeve provides an additional moulds and the tendency is towards higher ramming pres
(usually enclosed) Volume or cavity which is in communica sures which can result in breakage of the feeder sleeve and/or
tion with the mould cavity, so that molten metal also enters 25
breaker core when present, especially if the breaker core or
into the feeder sleeve. During solidification, molten metal the feeder sleeve is in direct contact with the pattern plate
within the feeder sleeve flows back into the mould cavity to prior to ram up.
compensate for the shrinkage of the casting. It is important
that metal in the feeder sleeve cavity remains molten longer The above problem is partly alleviated by the use of spring
than the metal in the mould cavity, so feeder sleeves are made 30 pins. The feeder sleeve and optional locator core (similar in
to be highly insulating or more usually exothermic, so that composition and overall dimensions to breaker cores) is ini
upon contact with the molten metal additional heat is gener tially spaced from the pattern plate and moves towards the
ated to delay solidification. pattern plate on ram up. The spring pin and feeder sleeve may
After solidification and removal of the mould material, be designed Such that after ramming, the final position of the
unwanted residual metal from within the feeder sleeve cavity 35 sleeve is such that it is not in direct contact with the pattern
remains attached to the casting and must be removed. In order plate and may be typically 5 to 25 mm distant from the pattern
to facilitate removal of the residual metal, the feeder sleeve surface. The knock off point is often unpredictable because it
cavity may be tapered towards its base (i.e. the end of the is dependent upon the dimensions and profile of the base of
feeder sleeve which will be closest to the mould cavity) in a the spring pins and therefore results in additional cleaning
design commonly referred to as a neck down sleeve. When a 40
costs. Other problems associated with spring pins are
sharp blow is applied to the residual metal it separates at the explained in EP-A-1 184104. The solution offered in EP-A-
weakest point which will be near to the mould (the process 1184104 is a two-part feeder sleeve. Under compression dur
commonly known as “knock off). A small footprint on the ing mould formation, one mould (sleeve) part telescopes into
casting is also desirable to allow the positioning of feeder the other. One of the mould (sleeve) parts is always in contact
sleeves in areas of the casting where access may be restricted 45
with the pattern plate and there is no requirement for a spring
by adjacent features.
Although feeder sleeves may be applied directly onto the pin. However, there are problems associated with the tele
Surface of the mould cavity, they are often used in conjunction scoping arrangement of EP-A-1 184104. For example, due to
with a breaker core. A breaker core is simply a disc of refrac the telescoping action, the volume of the feeder sleeve after
tory material (typically a resin bonded sand core or a ceramic 50 moulding is variable and dependent on a range of factors
core or a core of feeder sleeve material) with a hole in its including moulding machine pressure, casting geometry and
centre which sits between the mould cavity and the feeder sand properties. This unpredictability can have a detrimental
sleeve. The diameter of the hole through the breaker core is effect on feed performance. In addition, the arrangement is
designed to be smaller than the diameter of the interior cavity not ideally suited where exothermic sleeves are required.
of the feedersleeve (which need not necessarily be tapered) so 55 When exothermic sleeves are used, direct contact of exother
that knock off occurs at the breaker core close to the mould. mic material with the casting Surface is undesirable and can
Casting moulds are commonly formed using a moulding result in poor Surface finish, localised contamination of the
pattern which defines the mould cavity. Pins are provided on casting Surface and even Sub-Surface gas defects.
the pattern plate at predetermined locations as mounting Yet a further disadvantage of the telescoping arrangement
points for the feeder sleeves. Once the required sleeves are 60 of EP-A-1 184104 arises from the tabs or flanges which are
mounted on the pattern plate, the mould is formed by pouring required to maintain the initial spacing of the two mould
moulding sand onto the pattern plate and around the feeder (sleeve) parts. During moulding, these Small tabs break off
sleeves until the feeder sleeves are covered. The mould must (thereby permitting the telescoping action to take place) and
have sufficient strength to resisterosion during the pouring of simply fall into the moulding sand. Over a period of time,
molten metal, to withstand the ferrostatic pressure exerted on 65 these pieces will build up in the moulding sand. The problem
the mould when full and to resist the expansion/compression is particularly acute when the pieces are made from exother
forces when the metal solidifies. mic material. Moisture from the sand can potentially react
 US 7,500,509 B2
3 4
with the exothermic material (e.g. metallic aluminium) cre of the feeder element between its first and second ends is
ating the potential for Small explosive defects. shorter after compression than before compression. Prefer
ably, said compression is non-reversible i.e. it is important
SUMMARY OF THE INVENTION that after removal of the compression inducing force the
feeder element does not revert to its original shape. Compres
It is an object of the present invention in a first aspect to sion may be achieved through the inherent compressibility of
provide an improved feeder element which can be used in a the material from which the feeder element is formed, e.g.
cast moulding operation. In particular, it is an object of the rubber or other polymeric material. Thus, in a first embodi
present invention in its first aspect to provide a feeder element ment, the feeder element is a rubber tube.
which offers one or more (and preferably all) of the following 10 Alternatively, compression may be achieved through the
advantages: deformation of a non-brittle material Such as a metal (e.g.
(i) a smaller feeder element contact area (aperture to the steel, aluminium, aluminium alloys, brass etc) or plastic. In a
casting) second embodiment, the sidewall of the feeder element is
(ii) a small footprint (external profile contact) on the cast provided with one or more weak points which are designed to
ing Surface; 15 deform (or even shear) under a predetermined load (corre
(iii) reduced likelihood of feeder sleeve breakage under sponding to the crush strength).
high pressures during mould formation; and The sidewall may be provided with at least one region of
(iv) consistent knock off with significantly reduced clean reduced thickness which deforms under a predetermined
ing requirements. load. Alternatively or in addition, the sidewall may have one
A further object of the present invention is to obviate or or more kinks, bends, corrugations or other contours which
mitigate one or more of the disadvantages associated with the cause the sidewall to deform under a predetermined load
two-part telescoping feeder sleeve disclosed in EP-A- (corresponding to the crush strength).
1184104.
An object of a second aspect of the present invention is to In a third embodiment, the bore is frustoconical and
provide an alternative feeder system to that proposed in EP 25
bounded by a sidewall having at least one circumferential
A-1 184104.
groove. Said at least one groove may be on an interior or
According to a first aspect of the present invention, there is (preferably) exterior surface of the sidewall and provides in
provided a feeder element for use in metal casting, said feeder use a weak point which deforms or shears predictably under
an applied load (corresponding to the crush strength).
element having a first end for mounting on a mould pattern In a particularly preferred embodiment, the feeder element
(plate), an opposite second end for receiving a feeder sleeve 30
has a stepped sidewall which comprises a first series of side
and a bore between the first and second ends defined by a wall regions in the form of rings (which are not necessarily
sidewall, said feeder element being compressible in use planar) of increasing diameter interconnected and integrally
whereby to reduce the distance between said first and second formed with a second series of sidewall regions. Preferably,
ends.
It will be understood that the amount of compression and 35
the sidewall regions are of substantially uniform thickness, so
that the diameter of the bore of the feeder element increases
the force required to induce compression will be influenced from the first end to the second end of the feeder element.
by a number of factors including the material of manufacture Conveniently, the second series of sidewall regions are annu
of the feeder element and the shape and thickness of the lar (i.e. parallel to the bore axis), although they may be frus
sidewall. It will be equally understood that individual feeder toconical (i.e. inclined to the bore axis). Both series of side
elements will be designed according to the intended applica 40
wall regions may be of non-circular shape (e.g. oval, square,
tion, the anticipated pressures involved and the feeder size rectangular, or star shaped).
requirements. Although the invention has particular utility in
high Volume high-pressure moulding systems, it is also useful The compression behaviour of the feeder element can be
in lower pressure applications (when configured accordingly) altered by adjusting the dimensions of each wall region. In
Such as hand rammed casting moulds. 45 one embodiment, all of the first series ofsidewall regions have
Preferably, the initial crush strength (i.e. the force required the same length and all of the second series of sidewall
to initiate compression and irreversibly deform the feeder regions have the same length (which may be the same as or
element over and above the natural flexibility that it has in its different to the first series of sidewall regions). In a preferred
unused and uncrushed state) is no more than 5000 N. and embodiment however, the length of the first series of sidewall
more preferably no more than 3000 N. If the initial crush 50 regions varies, the wall regions towards the second end of the
strength is too high, then moulding pressure may cause the feeder element being longer than the sidewall regions towards
the first end of the feeder element.
feeder sleeve to fail before compression is initiated. Prefer
ably, the initial crush strength is at least 500 N. If the crush The feeder element may be defined by a single ring
strength is too low, then compression of the element may be between a pair of sidewall regions of the second series. How
initiated accidentally, for example if a plurality of elements 55 ever, the feeder element may have as many as six or more of
are stacked for storage or during transport. each of the first and the second series of sidewall regions.
The feeder element of the present invention may be Preferably, the angle defined between the bore axis and the
regarded as a breaker core as this term Suitably describes first sidewall regions (especially when the second sidewall
some of the functions of the element in use. Traditionally, regions are parallel to the axis of the bore) is from about 55 to
breaker cores comprise resin bonded sand or are a ceramic 60 90° and more preferably from about 70 to 90°. Preferably, the
material or a core of feeder sleeve material. However, the thickness of the sidewall regions is from about 4 to 24%,
feeder element of the current invention can be manufactured preferably from about 6 to 20%, more preferably from about
from a variety of other Suitable materials. In certain configu 8 to 16% of the distance between the inner and outer diam
rations it may be more appropriate to consider the feeder eters of the first sidewall regions (i.e. the annular thickness in
element to be a feeder neck. 65 the case of planar rings (annuli)).
As used herein, the term “compressible' is used in its Preferably, the distance between the inner and outer diam
broadest sense and is intended only to convey that the length eters of the first series of sidewall regions is 4 to 10 mm and
 US 7,500,509 B2
5 6
most preferably 5 to 7.5 mm. Preferably, the thickness of the FIGS. 9 and 10 are side and top elevations respectively of
sidewall regions is 0.4 to 1.5 mm and most preferably 0.5 to a third feeder element in accordance with the present inven
1.2 mm. tion,
In general, each of the sidewalls within the first and second FIG. 11 is a side elevation of a fourth feeder element in
series will be parallel so that the angular relationships accordance with the present invention,
described above apply to all the sidewall regions. However, FIGS. 12 and 13 are cross sections of a fifth feeder element
this is not necessarily the case and one (or more) of the in accordance with the present invention before and after
sidewall regions may be inclined at a different angle to the compression respectively,
bore axis to the others of the same series, especially where the FIGS. 14 and 15 are cross-sectional schematics of a feeder
sidewall region defines the first end (base) of the feeder ele 10 assembly incorporating a sixth feeder element in accordance
ment. with the present invention before and after compression
In a convenient embodiment, only an edge contact is respectively,
formed between the feeder element and casting, the first end FIG. 16 is a side elevation of a seventh feeder element in
(base) of the feeder element being defined by a sidewall 15
accordance with the present invention,
region of the first or second series which is non-perpendicular FIGS. 17 and 18 are cross sectional views of a feedersleeve
to the bore axis. It will be appreciated from the foregoing assembly incorporating an eighth embodiment of a feeder
discussion that such an arrangement is advantageous in mini element in accordance with the present invention,
mising the footprint and contact area of the feeder element. In FIGS. 19 and 20 are cross-sectional schematics of a feeder
such embodiments, the sidewall region which defines the first assembly incorporating a ninth feeder element in accordance
end of the feeder element may have a different length and/or with the present invention before and after compression
orientation to the other sidewall regions of that series. For respectively,
example, the sidewall region defining the base may be FIG. 21 is a plot of force applied against compression for
inclined to the bore axis at an angle of 5 to 30°, preferably 5 the breaker core of FIG. 7,
to 15°. Preferably, the free edge of the sidewall region defin 25 FIG.22 is a bar chart showing compression data for a series
ing the first end of the feeder element has an inwardly directed of breaker cores in accordance with the present invention,
annular flange or bead. FIG.23 is a plot of force against compression for a series of
Conveniently, a sidewall region of the first series defines breaker cores of the type shown in FIG. 7 differing in sidewall
the second end of the feeder element, said sidewall region thickness, and
preferably being perpendicular to the bore axis. Such an 30 FIGS. 24 and 25 show the feeder element of FIG. 1 and a
arrangement provides a suitable Surface for mounting of a different feeder sleeve to that shown in FIGS. 5 and 6
feeder sleeve in use.
mounted on a fixed pin before and after ram up respectively.
It will be understood from the foregoing discussion that the
feeder element is intended to be used in conjunction with a DETAILED DESCRIPTION OF PREFERRED
feeder sleeve. Thus, the invention provides in a second aspect 35 EMBODIMENTS
a feeder system for metal casting comprising a feeder element
in accordance with the first aspect and secured thereto a Referring to FIGS. 1 and 2, a feeder element in the form of
feeder sleeve.
a breaker core 10 has a generally frustoconical sidewall 12
The nature of the feeder sleeve is not particularly limited formed by pressing sheet Steel. An inner Surface of the side
and it may be for example insulating, exothermic or a com 40 wall 12 defines a bore 14 which extends through the breaker
bination of both, for example one sold by Foseco under the core 10 from its first end (base) 16 to its second end (top) 18,
trade name KALMIN, FEEDEX or KALMINEX. The feeder the bore 14 being of smaller diameter at the first end 16 than
sleeve may be conveniently secured to the feeder element by at the second end 18. The sidewall 12 has a stepped configu
adhesive but may also be push fit or have the sleeve moulded ration and comprises an alternating series of first and second
around part of the feeder element. 45 sidewall regions 12a, 12b. The sidewall 12 can be regarded as
a (first) series of mutually spaced annuli or rings 12a (of
BRIEF DESCRIPTION OF THE DRAWINGS which there are seven), each annulus 12a having an inner
diameter corresponding to the outer diameter of the preceding
Embodiments of the invention will now be described by annulus 12a, with adjacent annuli 12a being interconnected
way of example only with reference to the accompanying 50 by an annular sidewall region of the second series 12b (of
drawings in which: which there are six). The sidewall regions 12a, 12b are more
FIGS. 1 and 2 are side and top elevations respectively of a conveniently described with reference to the longitudinal axis
first feeder element in accordance with the present invention, of the bore 14, the first series of sidewall regions 12a being
FIGS. 3 and 4 show the feeder element of FIG. 1 and a radial (horizontal as shown) sidewall regions and the second
feeder sleeve mounted on a spring pin before and after ram up 55 series of sidewall regions 12b being axial (vertical as shown)
respectively, sidewall regions. The angle C. between the bore axis and the
FIG.3A is a cross section of part of the assembly of FIG.3. first sidewall regions 12a (in this case also the angle between
FIGS. 5 and 6 show the feeder element of FIG. 1 and a
adjacent pairs of sidewall regions) is 90°. Radial sidewall
regions 12a define the base 16 and the top 18 of the breaker
feeder sleeve mounted on a fixed pin before and after ram up 60 core 10. In the embodiment shown, the axial sidewall regions
respectively, 12b all have the same height (distance from inner diameter to
FIGS. 7 and 8 are side and top elevations respectively of a outer diameter), whereas the bottom two radial sidewall
second feeder element in accordance with the present inven regions 12a have a reduced annular thickness (radial distance
tion, between inner and outer diameters). The outer diameter of the
FIGS. 7A and 7B are cross sections of part of the feeder 65 radial sidewall region defining the top 18 of the breaker core
element of FIG. 7 mounted on a standard pin and a modified 10 is chosen according to the dimensions of the feeder sleeve
pin respectively, to which it is to be attached (as will be described below). The
 US 7,500,509 B2
7 8
diameter of the bore 14 at the first end 16 of the breaker core the base of the breaker core 30 does not splay outwardly under
10 is designed to be a sliding fit with a fixed pin. compression), produces a defined notch in the feeder neck to
Referring to FIG. 3, the breaker core 10 of FIG. 1 is aid knock off and ensures the knock off is close to the casting
attached by adhesive to a feeder sleeve 20, the breaker core/ Surface. The annular flange also provides for an accurate
feeder sleeve assembly being mounted on a spring pin 22 location on the pin whilst allowing free play between it and
secured to a pattern plate 24. The radial sidewall region 12a the axial sidewall region32. This is seen more clearly in FIG.
forming the base 16 of the breaker core 10 sits on the pattern 7A from which it can be seen that there is only an edge contact
plate 24 (FIG.3A). In a modification (not shown), the top 18 between the pattern plate 24 and the breaker core 30, thereby
of the breaker core 10 is provided with a series of through minimising the footprint of the feeder element. The remain
holes (for example six evenly spaced circular holes). The 10 ing axial and radial sidewall regions 12a, 12b have the same
breaker core 10 is secured to the feeder sleeve 20 by the length/height.
application of adhesive (e.g. hot melt adhesive) applied The knock off point is so close to the casting that in certain
between the two parts. When pressure is applied, adhesive is extreme circumstances it may be possible for the breaker core
partially squeezed out through the holes and sets. This set 30 to break off into the casting surface. Referring therefore to
adhesive serves as rivets to hold together the breaker core 10 15 FIG. 7B, it may be desirable to provide a short (about 1 mm)
and feeder sleeve 20 more securely. stub 36 at the base of the pin (fixed or spring) on which the
In use, the feeder sleeve assembly is covered with mould breaker core 30 sits. This is conveniently achieved by forming
ing sand (which sand also enters the Volume around the the pattern plate 24 with a suitably raised region on which the
breaker core 10 below the feeder sleeve 20) and the pattern pin is mounted. Alternatively, the stub may be in the form of
plate 24 is “rammed up' whereby to compress the moulding a ring formed either as part of the pattern plate 24, at the base
sand. The compressive forces cause the sleeve 20 to move of the pin, or as a discrete member (e.g. a washer) which is
downwardly towards the pattern plate 24. The forces are placed over the pin before the breaker core 30 is mounted on
partially absorbed by the pin 22 and partially by the deforma the pin.
tion or collapse of the breaker core 10 which effectively acts Referring to FIGS. 9 and 10, a further breaker core 40 in
as a crumple Zone for the feeder sleeve 20. At the same time, 25 accordance with the invention is Substantially the same as that
the moulding medium (sand) trapped under the deforming shown in FIGS. 7 and 8, except that the sidewall 42 defining
breaker core 10 is also progressively compacted to give the the base of the breaker core 40 is frustoconical, tapering
required mould hardness and surface finish below the breaker axially outwardly from the base of the breaker core at an angle
core 10 (this feature is common to all embodiments in which of about 20° to 30° to the bore axis. The sidewall 42 is
the downwardly tapering shape of the feeder element permits 30 provided with an annular flange 42a in the same manner and
moulding sand to be trapped directly below the feeder sleeve). for the same purpose as the embodiment shown in FIG. 7. The
In addition, compaction of the sand also helps to absorb some breaker core 40 has one fewer step (i.e. one fewer axial and
of the impact. It will be understood that since the base 16 of radial sidewall region 12a, 12b) than the breaker core 30
the breaker core 10 defines the narrowest region in commu shown in FIG. 7.
nication with the mould cavity, there is no requirement for the 35 Referring to FIG. 11, a further breaker core 50 in accor
feeder sleeve 20 to have a tapered cavity or excessively taper dance with the invention is shown. The basic configuration is
ing sidewalls which might reduce its strength. The situation similar to that of the previously described embodiment. The
after the ram up is shown in FIG. 4. Casting is effected after pressed metal sidewall is stepped to provide a bore 14 of
removal of the pattern plate 24 and pin 22. increasing diameter towards the second (top) end 52 of the
Advantageously, the feeder element of the present inven 40 breaker core 50. In this embodiment however, the first series
tion does not depend on the use of a spring pin. FIGS. 5 and of sidewall regions 54 are inclined by about 45° to the bore
6 illustrate the breaker core 10 fitted to a feeder sleeve 20a axis (i.e. frustoconical) so that they are outwardly flared rela
mounted on a fixed pin 26. Since on ram up (FIG. 6), the tive to the base 56 of the breaker core 50. The angle C. between
sleeve 20a moves downwardly and the pin 26 is fixed, the the sidewall regions 54 and the bore axis is also 45°. This
sleeve 20a is provided with a bore 28 within which the pin 26 45 embodiment has the preferred feature that the first series of
is received. As shown, the bore 28 extends through the top radial sidewall regions 54 are the same length as the axial
surface of the sleeve 20a, although it will be understood that sidewall regions 12b such that on compression the profile of
in other embodiments (not shown) the sleeve may be provided the resultant deformed feeder element is relatively level (hori
with a blind bore (i.e. the bore extends only partially through Zontal). The breaker core 50 comprises only four axial side
the top section of the feeder so that the riser sleeve cavity is 50 wall regions 54 of the first series. The sidewall region 58 of
enclosed). In a further variation (shown in FIG. 24) a blind the second series 12b terminates at the base 56 of the breaker
bore is used in conjunction with a fixed pin, the sleeve being core 50 and is significantly longer than the other sidewall
designed so that on ram up the pinpierces the top of the feeder regions 12b of the second series.
sleeve as shown in FIG. 25 (and described in DE 19503456), Referring to FIGS. 12 and 13, a further breaker core 60 is
thus creating a vent for mould gasses once the pin is removed. 55 shown. The breaker core 60 has a frustoconical bore 62
Referring to FIGS. 7 and 8, the breaker core 30 shown defined by a metal sidewall 64 of substantially uniform thick
differs from that illustrated in FIG. 1 in that the sidewall ness into an external Surface of which three mutually spaced
region 32 defining the base of the breaker core 30 is axially concentric grooves 66 have been provided (in this case by
orientated and its diameter corresponds Substantially to the machining). The grooves 66 introduce weak points into the
diameter of the pin 22.26. This axial sidewall region 32 is also 60 sidewall 64 which fail predictably on compression (FIG. 13).
extended to have a greater height than the otheraxial sidewall In variations of this embodiment (not shown) a series of
regions 12b, to allow for some depth of compacted sand discrete notches is provided. Alternatively, the sidewall is
below the breaker core 30. In addition, the free edge of the formed with alternating relatively thick and relatively thin
axial sidewall region 32 defining the base has an inwardly regions.
orientated annular flange 32a which sits on the pattern plate in 65 A yet further breaker core in accordance with the present
use and which strengthens the lower edge of the bore and invention is shown in FIGS. 14 and 15. The breaker core 70 is
increases the contact area to the pattern plate 24 (ensuring that a thin side walled steel pressing. From its base, the sidewall
 US 7,500,509 B2
10
has an outwardly flared first region 72a, a tubular, axially base of the spring pins) and in some cases hand dressing of the
orientated second region 72b of circular cross section, and a stubs would have been required adding to the manufacturing
third radially outwardly extending region 72c, the third region cost of the casting.
72c serving as a seat for a feeder sleeve 20 in use. Under
compression, the breaker core 70 collapses in a predictable EXAMPLE 1 a
manner (FIG. 15), the internal angle between the first and
second sidewall regions 72a, 72b decreasing. The breaker core of FIG. 1 (axial length 30 mm, minimum
It will be understood that there are many possible breaker diameter 30 mm, maximum diameter 82 mm corresponding
cores with different combinations of orientated sidewall to the outside diameter of the base of the sleeve) manufac
regions. Referring to FIG. 16, the breaker core 80 illustrated 10 tured from 0.5 mm Steel attached to a FEEDEX HD-VS159
is similar to that illustrated in FIG. 11. In this particular case exothermic sleeve was mounted on either a fixed pin or a
one series of radially orientated (horizontal) sidewall regions spring pin. No visible damage was observed to the feeder
82 alternates with a series of axially inclined sidewall regions sleeve after moulding and it was observed that there was
84. Referring to FIGS. 17 and 18, the breaker core 90 has a excellent sand compaction of the mould in the area directly
Zig-Zag configuration formed by a first series of outwardly 15 below the breaker core. The knock off point was repeatable
axially inclined sidewall regions 92 alternating with a series and close to the casting Surface. In some cases, the residual
of inwardly axially inclined sidewall regions 94, inwardly and feeder metal and breaker core actually fell off during casting
outwardly being defined from the base up. In this embodi shakeout from the greensand mould, obviating the need for a
ment, the breaker core is mounted on the pin 22 indepen knock off step. There were no surface defects on the casting
dently of the sleeve 20, which sits on the breaker core, but is and no adverse implications in having the steel breaker core in
not secured thereto. In a modification (not shown) an upper direct contact with the iron casting Surface.
radial surface defines the top of the breaker core and provides
a seating surface for the sleeve which can be pre-adhered to EXAMPLE1b.
the breaker core if required.
Referring to FIGS. 19 and 20, another breaker core 100 in 25 A further trial was conducted with a breaker core of FIG.7
accordance with the present invention is shown. The breaker (axial length 33 mm, minimum diameter 20 mm, maximum
core 100 consists simply of a tubular rubber sheath which is a diameter 82 mm corresponding to the outside diameter of the
sliding fit on the pin 22 and which provides a seat for the base of the sleeve) manufactured from 0.5 mm steel attached
sleeve 20. Upon ram up the sheath is axially compressed to a FEEDEX HD-VS159 exothermic sleeve. This was used
(FIG. 20). 30 for a different model design of gear housing casting with a
more contoured and uneven profile to the casting in the pre
TEST EXAMPLES vious example, and was similarly mounted on either a fixed
pin or a springpin. Knockoff was again excellent as was sand
Testing was conducted on a commercial Kunkel-Wagner compaction of the mould in the area directly below the
high-pressure moulding line No. 09-2958, with a ram up pres 35 breaker core. The use of this breaker core (as compared to that
sure of 300 tonnes and moulding box dimensions of 1375x in Example 1a) provided the beneficial opportunity for a
975x390/390 mm. The moulding medium was a clay-bonded smaller footprint and reduced contact area of the feeder ele
greensand system. The castings were central gear housings in ment with the casting Surface.
ductile cast iron (spheroidal graphite iron) for automotive 40 EXAMPLE 1 c
SC.

A third trial was conducted with a breaker core of FIG. 9

COMPARATIVE EXAMPLE1
(axial length 28 mm, maximum diameter 82 mm correspond
ing to the outside diameter of the base of the sleeve and
AFEEDEX HD-VS159 feeder sleeve (fast-igniting, highly 45 sidewall 42 tapering axially outwardly from the base at an
exothermic and pressure resistant) attached to a Suitable silica angle of 18 to the bore axis) manufactured from 0.5 mm steel
sand breaker core (10O) was mounted directly on the pattern attached to a FEEDEX HD-VS159 exothermic sleeve. This
plate with a fixed pin to locate the breaker core/feeder sleeve was used for a number of different designs of gear housing
arrangement on the pattern plate prior to moulding. Although castings including those used in examples 1a and 1b. The
the knock off point was repeatable and close to the casting 50 breaker core/feeder sleeve arrangement was mounted on
Surface, damage (primarily cracking) due to the moulding either a fixed pin or a spring pin. The combination of the
pressure was evident in a number of the breaker cores and the tapered sidewall 42 and annular flange 42a at the base of the
sleeves. breaker core resulted in a highly defined notch and taper in the
feeder neck resulting in excellent knock off of the feeder
COMPARATIVE EXAMPLE 2 55 head, which was highly consistent and reproducible, very
close to the casting Surface and thus requiring minimal
AFEEDEX HD-VS159 feeder sleeve (fast-igniting, highly machining of the stubs to produce the finished casting.
exothermic and pressure resistant) attached to a suitable loca
tor core (50HD) was used as in comparative example 1, but in EXAMPLE 2
this case a spring pin was used for mounting the locator 60
core/feeder sleeve arrangement on and above the pattern plate Investigation of Crush Strength and Sidewall
prior to moulding. On moulding the pressure forced down the Configuration
locator core/feeder sleeve arrangement and spring pin, and
moulding sand flowed under and was compacted below the Breaker cores were tested by sitting them between the two
locator core. No visible damage was observed in the breaker 65 parallel plates of a Hounsfield compression strength tester.
core or sleeve after moulding. However, the knock off point The bottom plate was fixed, whereas the top plate traversed
was not repeatable (due to the dimensions and profile of the downwards via a mechanical screw thread mechanism at a
 US 7,500,509 B2
11 12
constant rate of 30 mm perminute and graphs of force applied mum crush strength) can be tailored to the particular appli
against plate displacement were plotted. cation intended for the breaker core.
The breaker cores tested had the basic configuration shown The invention claimed is:
in FIG. 11 (sidewall regions 12b and 54 being 5mm, sidewall 1. A feeder element for use in metal casting, said feeder
region 58 being 8 mm and defining abore ranging from 18 to 5
element having a first end for mounting on a mould pattern, an
25 mm, and the maximum diameter of the top 52 of the opposite second end for receiving a feeder sleeve and a bore
breaker core being 65 mm). In all, ten different breaker cores between the first and second ends defined by a stepped side
were tested, the only differences between the cores being wall which comprises a first series of sidewall regions in the
angle C, which varied from 45 to 90° in 5 intervals and the form of rings of increasing diameter interconnected and inte
length of the top outer sidewall region, which was adjusted so 10
grally formed with a second series of Sidewall regions, said
that the maximum diameter of the top 52 of the breaker core feeder element being irreversibly compressible in use
was 65 mm for all breaker cores. The metal thickness of the
metal breaker cores was 0.6 mm.
whereby to reduce the distance between said first and second
Referring to FIG. 21, force is plotted against plate displace ends, wherein an initial crush strength in response to a force
ment for a breaker core with C=50°. It will be noted that as 15
applied between the first and second ends is no more than
5OOON.
force is increased, there is minimal compression (associated 2. A feeder element as claimed in claim 1, wherein the
with the natural flexibility in its unused and uncrushed state) initial crush strength is at least 500 N.
of the breaker core until a critical force is applied (point A), 3. A feeder element as claimed in claim 1, wherein com
referred to herein as the initial crush strength, after which pression is achieved through the deformation of a non-brittle
compression proceeds rapidly under a lower loading, with material.
point B marking the minimum force measurement after the 4. A feeder element as claimed in claim 1, wherein said
initial crush strength occurs. Further compression occurs and rings are circular.
the force increases to a maximum (maximum crush strength, 5. A feeder element as claimed in claim 1, wherein said
point C). When the core has reached or is close to its maxi rings are planar.
mum displacement (point D) the force increases rapidly off 25
6. A feeder element as claimed in claim 1, wherein the
scale at the point where physically no further displacement is sidewall regions are of Substantially uniform thickness, so
possible (point E). that the diameter of the bore of the feeder element increases
The initial crush strengths, minimum force measurements from the first end to the second end of the feeder element.
and maximum crush strengths are plotted in FIG.22 for all ten 7. A feeder element as claimed in claim 1, wherein the
breaker cores. Ideally, the initial crush strength should be 30
second series of sidewall regions are parallel to the bore axis.
lower than 3000N. If the initial crush strength is too high then 8. A feeder element as claimed in claim 1, wherein the
moulding pressure may cause failure of the feeder sleeve angle defined between the bore axis and the first sidewall
before the breaker core has a chance to compress. An ideal regions is from about 55 to 90°.
profile would be a linear plot from initial crush strength to 9. A feeder element as claimed in claim 1, wherein the
maximum crush strength, therefore the minimum force mea 35
sidewall region defining the first end of the feeder element is
surement (point B) would ideally be very close to the mini inclined to the bore axis by an angle of 5 to 30°.
mum crush strength. The ideal maximum crush strength is 10. A feeder element as claimed in claim 1, wherein the
very much dependent on the application for which the breaker thickness of the sidewall regions is from about 4 to 24% of the
core is intended. If very high moulding pressures are to be distance between the inner and outer diameters of the first
applied thena higher maximum crush strength would be more 40
sidewall regions.
desirable than for a breaker core to be used in a lower moul
ding pressure application. 11. A feeder element as claimed in claim 10, wherein a free
edge of the sidewall region defining the first end of the feeder
EXAMPLE 3 element has an inwardly directed annular flange.
45 12. A feeder element as claimed in claim 1, wherein the
Investigation of Crush Strength and Sidewall sidewall of the feeder element is provided with one or more
Thickness weak points which are designed to deform or shear in use
under a predetermined load.
In order to investigate the effect of metal thickness on the 13. A feeder element as claimed in claim 12, wherein the
crush strength parameters, further breaker cores were made 50 sidewall is provided with at least one region of reduced thick
and tested as for example 2. The breaker cores were identical ness which deforms under a predetermined load.
to those used in Example 1b (axial length 33 mm, minimum 14. A feeder element as claimed in claim 12, wherein the
diameter 20 mm, maximum diameter 82 mm corresponding sidewall is provided with one or more kinks, bends, or corru
to the outside diameter of the base of the sleeve). The steel gations which cause the sidewall to deform under a predeter
thickness was 0.5,0.6 or 0.8 mm (corresponding to 10, 12 and 55 mined load.
16% of sidewall 12a annular thickness). The plots of force 15. A feeder element as claimed in claim 12, wherein the
against displacement are shown in FIG. 23, from which it can bore is frustoconical and bounded by a sidewall having at
be seen that the initial crush strength (points A) increases with least one circumferential groove.
metal thickness, as does the difference between the minimum 16. A feeder element as claimed in claim 1 wherein the
force (points B) and the initial crush strength. If the metal is 60 feeder element is made from a metal selected from steel,
toothick relative to the sidewall region 12a annular thickness, aluminum, aluminum alloys and brass.
then the initial crush strength is unacceptably high. If the 17. A feeder element as claimed in claim 1 wherein the
metal is too thin, then the crush strength is unacceptably low. feeder element is made from steel.
It will be understood from a consideration of Examples 2 18. A feeder element as claimed in claim 1 wherein the
and 3, that by changing the geometry of the breaker core and 65 crush strength is at least 500 N and no more than 3000 N.
the thickness of the breaker core material, the three key 19. A feederas claimed in claim 1 wherein the thickness of
parameters (initial crush strength, minimum force and maxi the sidewall regions is 0.4 to 1.5 mm.
 US 7,500,509 B2
13 14
20. A feeder system for metal casting comprising a feeder wherein the feeder element has a first end and an oppo
element and a feeder sleeve said feeder element having a first site second end and a bore between the first and second
end for mounting on a mould pattern, an opposite second end ends defined by a sidewall, the feeder sleeve having an
to which the feeder sleeve is secured and a bore between the opening at one end thereof in communication with the
first and second ends, said feeder sleeve having an opening at bore of the feeder element, said feeder sleeve being
one end thereof in communication with the bore of the feeder secured to the feeder element at the second end of the
element, said feeder sleeve being secured to the second end of feeder element such that a flowpath exists through the
the feeder element at said one end of the feeder sleeve, bore and into the feeder sleeve, the feeder element hav
wherein the feeder element is irreversibly compressible in use ing an initial crush strength of no more than 5000 N
whereby to reduce the distance between said first and second 10 measured along the bore axis;
ends, and wherein an initial crush strength of the feeder mounting the first end of the feeder element on the mould
element in response to a force applied in a direction of the pattern;
bore axis is no more than 5000 N. pouring Sufficient moulding sand onto the mould pattern to
21. A feeder system in accordance with claim 20, in which cover the feeder sleeve; and
the feeder sleeve is secured to the feeder element by adhesive 15 applying a compressive force to the moulding sand in the
or by being a push fit with the feeder element or by moulding general direction of the bore axis of the feeder element,
the sleeve around part of the feeder element. Such that the sand compacts and the feeder element
22. A method of forming one part of a casting mould, said compresses irreversibly whereby the distance between
the first and second ends of the feeder element is
method comprising, reduced.
providing a mould pattern and a feeder system, said feeder
system comprising a feeder sleeve and a feeder element,