WO2014055082A1

WO2014055082A1 - Composite casting wheels

Info

Publication number: WO2014055082A1
Application number: PCT/US2012/058763
Authority: WO
Inventors: Jiri NECAS; Mark Brian VINCENT
Original assignee: Pyrotek Inc
Current assignee: Pyrotek Inc
Priority date: 2012-10-04
Filing date: 2012-10-04
Publication date: 2014-04-10
Anticipated expiration: 2015-04-04

Description

COMPOSITE CASTING WHEELS

BACKGROUND

[0001] Casting wheels formed of metal exist for pouring molten aluminum into ingot molds on a conveyor system.

[0002] However, these metal casting wheels conduct heat from the molten aluminum. Because the metal casting wheels conduct heat from the molten aluminum, the casting process requires higher casting temperatures. The higher casting temperatures produce more impurities, which to remove the byproducts adds complexity to the casting process. For example, because of the higher temperatures demanded by the metal casting wheel, existing casting processes produce more dross (i.e., masses of solid impurities thrown off of molten metal). Typically, more dross is formed in the ingot molds, the troughs, and the furnace. Subsequently complicated and time consuming processes are added to the casting process to remove the dross. In addition to adding complicated and time consuming processes to remove the dross, the removal of the dross causes a loss of aluminum. That is, typically a portion of the molten aluminum is removed along with the dross. Further, the higher temperatures required by the metal casting wheel cause a higher level of gassing of the molten aluminum. That is, the higher temperatures required by the metal casting wheel cause a higher level of affinity of the molten aluminum to pick up hydrogen from the air. Subsequently, complicated and time consuming processes are added to the casting process to remove the hydrogen picked up by the molten aluminum. In addition, iron contamination is typical due to the continual corrosion of the metallic wheel. [0003] Thus, there remains a need to develop new casting wheels formed of composite materials that don't demand higher casting temperatures and eliminate iron contamination.

BRIEF SUMMARY

[0004] This Brief Summary is provided to introduce simplified concepts relating to composite casting wheels, which are further described below in the Detailed Description. This Summary is not intended to identify essential features of the claimed subject matter, nor is it intended for use in determining the scope of the claimed subject matter.

[0005] This disclosure relates to composite wheels for casting molten metal (e.g., molten aluminum). In some embodiments, such composite wheels may be configured to insulate the molten metal in the composite wheels and thereby lower the casting temperature of the molten metal.

[0006] In some embodiments, the composite wheels may include a rim formed of a composite material (e.g., a ceramic), and a plurality of spouts removeably coupled to the rim.

[0007] In some embodiments, the rim may be formed as a single unit of the composite material. For example, the rim may be one contiguous unit formed of the composite material.

[0008] In some embodiments, the rim may be formed from a plurality of segments. For example, the each segment may be formed of the composite material and configured to cooperate (e.g., interlock, link, fit together, etc.) to form the rim of the composite wheel.

[0009] In some embodiments, the plurality of spouts may be removeably coupled to the rim via an adhesive.

BRIEF DESCRIPTION OF THE DRAWINGS

[0010] The Detailed Description is set forth with reference to the accompanying figures. In the figures, the left-most digit(s) of a reference number identifies the figure in which the reference number first appears. The use of the same reference numbers in different figures indicates similar or identical items.

[0011] FIG. 1 illustrates an example casting wheel comprising a rim formed of a composite material, and a plurality of spouts removeably coupled to the rim.

[0012] FIG. 2 illustrates a detail section view of the illustrative casting wheel illustrated in FIG. 1 taken along line A— A.

[0013] FIGS. 3 and 4 are flow diagrams illustrating example processes of installing the illustrative casting wheel illustrated in FIG. 1 in a casting facility.

DETAILED DESCRIPTION

Overview

[0014] As noted above, existing casting wheels formed of metal demand higher casting temperatures which produce dross, iron contamination and gassing in the molten metal. This application describes casting wheels formed of composites that insulate the molten metal and exhibit lower casting temperatures compared with existing casting wheels formed of metal. This application also describes various techniques for installing such composite casting wheels at casting facilities. By way of example and not limitation, this application describes the composite casting wheels being used in the field of ingot casting. For example, this application describes the composite casting wheels being used in the field of aluminum ingot casting. However, the composite casting wheels may be used in other fields. For example, the composite casting wheels may be used in the field of investment casting, sand casting, shell-mold casting, or the like.

[0015] In general, composite casting wheels as described in this application include a rim formed of a composite material, and a plurality of spouts removeably coupled to the rim to pour molten metal from the composite casting wheel to respective permanent molds arranged in a conveyor system.

[0016] In some embodiments, the composite materials may comprise a fibrous material (e.g., individual threads, a fabric, patches or segments of a fabric, chopped fibers, etc.) embedded in a ceramic matrix. For example, the composite materials may comprise a fiberglass fabric embedded in a calcium silicate Ca₂Si0₄ slurry as described in a white paper titled Development And Use Of A New Composite Material For Aluminium Contact Applications and edited by The Minerals, Metals, and Materials Society (TMS) in 2004, the contents of which are incorporated in its entirety herein. U.S. Patent No. 5,154,955 titled Fiber-Reinforced Cement Composition describes other composite materials that may be used to form the composite casting wheels, the contents of which are incorporated in its entirety herein. [0017] In some examples, the composite materials may comprise a ceramic void of fabric. For example, the composite materials may comprise a fused silica. By way of example and lot limitation, this application describes the rim formed of the fabric embedded in the ceramic, and the spouts formed of the fused silica. However, the rim and the spouts may be formed of any composite material suitable for being used to cast molten metal. For example, the rim and/or the spouts may be formed of a fibrous material embedded in a ceramic matrix containing fused silica, silicon carbide, alumina, calcium silicate, bauxite, combinations of any of these, or other refractory materials. Further, both the rim and the spouts may be formed of the same composite material. For example, both the rim and the spouts may be formed of a composite material comprising a fabric embedded in the ceramic. Additionally, metallic inserts may be embedded into the ceramic composite material. For example, metallic inserts may be embedded into the ceramic composite wheel to provide for technical requirements (e.g., external attachments, fixings, fittings, wear surfaces, etc.).

[0018] Because the composite casting wheels are formed of these ceramic materials, the composite casting wheels provide properties suitable for casting molten aluminum. For example, the ceramic materials forming the composite casting wheels insulate the molten aluminum contained by the composite casting wheels. Thus, because the heat transfer rate from the molten aluminum to the composite casting wheel is significantly reduced, a temperature of the molten aluminum being received by the composite wheel can be reduced, as compared to a temperature of the molten aluminum being received by the existing casting wheels formed of metal. This is, because the composite casting wheels insulate the molten aluminum, the molten aluminum remains at a temperature suitable to be poured into respective ingot molds. As compared to the casting wheels formed of metal, which act as a heat sink, transferring heat from the molten aluminum to the metal casting wheel. Thus, to keep the temperature of the molten aluminum in the metal casting wheel at a temperature suitable to be poured into the respective ingot molds, the molten aluminum received by the metal casting wheel is at a higher or elevated temperature to make up a difference in heat loss by the metal casting wheel. In one test example, a 60 degree C (140 degrees F) reduction in a casting temperature was observed. The lower casting temperatures allowed by the composite casting wheels reduces the amount of energy (i.e., combustion energy) required to cast the aluminum ingots. The reduced amount of energy consumption reducing C0₂ output and lowering energy costs.

[0019] Further, the lower casting temperatures allowed by the composite casting wheels, as compared to the higher casting temperatures required by the existing metal casting wheels, reduces the amount of dross in the casting system. For example, the lower casting temperatures allowed by the composite casting wheels reduces the amount of dross floating on the ingots, reduces the amount of dross in the launder, and reduces the amount of dross in the melting furnace. Because the lower casting temperatures allowed by the composite casting wheels reduce the amount of dross in the casting system, the casting process is simplified. For example, by reducing the dross floating on the ingots, this reduces the need to add a process in the casting process to remove the floating dross. In one example, by reducing the dross floating on the ingots, this may eliminate the need to add a process in the casting process to have robots remove the floating dross. In addition to simplifying the casting process, because the composite casting wheel reduces the amount of dross being removed, this reduces an amount of lost aluminum in the casting process. For example, during the removal of the floating dross on the ingots some aluminum is also removed along with the floating dross. Thus, because there is less floating dross being removed from the ingots, there is less aluminum being removed from the ingots, reducing the amount of lost aluminum in the casting process.

[0020] Further, because the lower casting temperatures allowed by the composite casting wheels, as compared to the higher casting temperatures demanded by the existing metal casting wheels, less aluminum is lost to oxidation of the aluminum. In one example, the higher casting temperatures required by the metal casting wheels oxidizes about 3% of the aluminum being cast. Thus, the lower casting temperatures allowed by the composite casting wheels reduces the amount of aluminum being lost during the casting of the aluminum.

[0021] Further, the lower casting temperatures allowed by the composite casting wheels, as compared to the higher casting temperatures required by the existing metal casting wheels, improves a usable life of refractories in the casting system. For example, the lower casting temperatures allowed by the composite casting wheels reduces the temperatures exposed to the refractory materials in the launder, and in the melting furnace. Exposing the refractories in the launder and the melting furnace to lower casting temperatures extends the usable life of the refractories.

[0022] Further, the lower casting temperatures allowed by the composite casting wheels, as compared to the higher casting temperatures required by the existing metal casting wheels, reduces the amount of gassing. For example, the lower casting temperatures allowed by the composite casting wheels reduces an amount of hydrogen captured by the molten aluminum from the air.

[0023] In another example where the composite casting wheels provide properties suitable for casting molten aluminum, the ceramic materials forming the composite casting wheels chemically resist the molten aluminum contained by the composite casting wheels. Thus, because of the composite casting wheels' excellent aluminum chemical resistance, the composite casting wheels produce a cleaner product free of iron contamination. For example, the ceramic materials forming the composite casting wheels may not interact or react with the molten aluminum, leaving the molten aluminum free of any composite material forming the composite casting wheels. As compared to a casting wheel formed of metal (e.g., cast iron or steel) where the metal interacts or reacts with the molten aluminum, leaving the molten aluminum contaminated with the metal forming the casting wheel.

[0024] In some embodiments, the rim may be formed as a single unit of the composite material. For example, the rim may be formed as a single unit of composite material. In one specific example, the rim may be formed as a single unit of a fabric embedded in a ceramic. In other embodiments, the rim may be formed as a plurality of segments of the composite material. For example, the rim may be formed from two or more cooperating segments formed of the composite material, and configured to fit together to form the rim. The rim may have an inner surface opposite an outer surface. The inner surface may define a trough to receive the molten metal.

[0025] In some embodiments, the plurality of spouts may be removeably coupled to the rim, and interconnected with the trough to pour molten metal into respective molds fixed in a conveyor when the composite casting wheel is rotated above a conveyor.

[0026] These and other aspects of the composite casting wheels will be described in greater detail below with reference to several illustrative embodiments.

Example Composite Casting Wheels

[0027] This section describes an exemplary casting wheels formed of a composite material.

[0028] In some implementations, the composite casting wheels include a rim formed as a single unit of a composite material. In some implementations, the rim may be formed from a two or more segments formed a composite material. In some implementations, a plurality of spouts are removeably coupled to the composite rim. These and numerous other composite casting wheels are described in this section.

[0029] FIG. 1 illustrates an example casting wheel 102 comprising a rim 104 formed of a composite material, and a plurality of spouts 106 removeably coupled to the rim 104. While FIG. 1 illustrates the plurality of spouts 106 being removeably coupled to the rim 104, the plurality of spouts 106 may be formed integral with the rim 104. For example, the plurality of spouts 106 and the rim 104 may be formed as a single unit of the composite material, and fixed to the rim 104. Further, the plurality of spouts 106 may be permanently fixed to the rim via an adhesive. The rim 104 may have an inner surface 108 opposite an outer surface 1 10. The inner surface 108 of the rim 104 defining a trough 1 12 to receive molten metal (e.g., molten aluminum). For example, the casting wheel 102 may be arranged above a conveyor 114 having respective permanent molds 1 16 moving in a linear direction 118 below the casting wheel 102, and a launder 120 may provide (e.g., spill, pour, dispense, feed, etc.) molten metal 122 into the trough 1 12 of the rim 104. The inner surface 108 may be substantially void of dimples, bumps, ridges, etc. to provide a smooth surface, and thus produce a laminar flow of the molten metal 122 in the trough 1 12. The inner surface 108 may include features to provide for uniformly dispense the molten metal 122 in the trough 112 into the ingots below. For example, the inner surface 108 may include dimples, bumps, ridges, etc. to uniformly dispense the molten metal 122 in the trough 1 12 into the ingots below.

[0030] The rim 104 may be formed as a single unit 124 of the composite material. For example, the rim 104 may be formed as one contiguous unit of the composite material. As shown in detail view 126, the rim 104 may be formed from a plurality of segments 128(1) through 128(N). In this embodiment, the plurality of segments 128(1) and 128(N) may be configured to cooperate together to form the rim 104. For example, two or more segments 128(1) and 128(N) may include interlocking surfaces 130(A) and 130(B) that when mated together form the rim 104. An outer member 132 may be arranged around the two or more segments 128(1) and 128(N) to secure the two or more segments 128(1) and 128(N) together. For example, an outer metal rim may be arranged around the segments 128(1) and 128(N), and retain the segments 128(1) through 128(N) around an inside diameter of the outer metal rim. For example, the outer metal rim may be configured to have an inside surface arranged around the inside diameter of the outer metal rim for receiving the segments 128(1) through 128(N). The segments 128(1) through 128(N) arranged around the inside diameter of the outer metal rim forming a refractory liner of the outer metal rim. The segments 128(1) through 128(N) arranged around the inside diameter of the outer metal rim defining a casting wheel. Further, the outer member 132 may be a band, a strap, a binder, etc., arranged around the segments 128(1) and 128(N) to retain the segments 128(1) through 128(N) together.

[0031] While detail view 126 illustrates two segments 128(1) and 128(N), any number of segments 128(1) through 128(N) may cooperate together to form the rim 104. In one example, 24 segments 128(1) through 128(24) may cooperate together to form the rim 104. In this example, where 24 segments cooperate to form the rim 104, each segment 128(1) through 128(24) may removeably receive one of the plurality of spouts 106. However, in other embodiments any number of spouts 106 may be removeably received by each of the plurality of segments 128(1) through 128(N). For example, a plurality of multiple spouts, smaller than the spouts 106, may be removeably coupled to each of the plurality of segments 128(1) through 128(24).

[0032] Further, each of the plurality of segments 128(1) through 128(N) may be formed of the composite material. For example, each of the plurality of segments 128(1) through 128(N) may be formed of a fabric embedded in a ceramic.

[0033] FIG. 1 illustrates the plurality of spouts 106 may be arranged radially 134 in the outer surface 110 to pour the molten metal 122 into the respective molds 1 16. For example, the plurality of spouts 106 may be arranged radially 134 in the outer surface 110 and have a degree of separation 136 substantially the same as a distance 138 between the respective molds 1 16. In one example, the plurality of spouts 106 may have a degree of separation 136 of at least about 15 degrees. For example, there may be about 15 degrees of separation between each center of each spout 106. While FIG. 1 illustrates a degree of separation of about 15 degrees, in other embodiments any degree of separation may be implemented. For example, the plurality of spouts 106 may have any degree of separation depending on a conveyor 1 14 the casting wheel 102 is to interface with. That is, the plurality of spouts 106 may have a degree of separation 136 larger than 15 degrees if the distance 138 in the conveyor 114 is larger, or the plurality of spouts 106 may have a degree of separation 136 smaller than 15 degrees if the distance 138 in the conveyor 114 is smaller.

[0034] The casting wheel 102 may be installed on an axle (not shown) via a plurality of apertures 140 arranged in a wall 142 of the casting wheel 102. In one example, the casting wheel 102 may be positioned (e.g., lifted) adjacent to the axle to be fastened via threaded fasteners (e.g., nuts and bolts) to the axle. Because the casting wheel 102 may be formed of the composite material, the composite casting wheel weighs less than a casting wheel formed of metal (e.g., cast iron or steel). For example, the casting wheel 102 formed of the composite material may weigh about 10 Kilograms (22 Pounds) as compared to a metal casting wheel weighing about 100 Kilograms (220 Pounds). Thus, the casting wheel 102 formed of the composite is much lighter and may be installed by a single installer without the use of a crane. Further, because the casting wheel 102 is much lighter than a metal casting wheel the time to install the casting wheel 102 reduced as compared to installing the heavier metal casting wheel.

[0035] FIG. 1 also illustrates a section line A— A. The section line A— A is taken approximate to a center of the casting wheel 102. [0036] FIG. 2 illustrates a detail section view of the illustrative casting wheel 102 illustrated in FIG. 1 taken along the section line A— A. FIG. 2 illustrates that each of the plurality spouts 106 removeably coupled to the rim 104 may include a lip 202 opposite a base 204. An array of apertures 206 may be arranged around the rim 104. Each aperture 206 may extend through the inner surface 108 and the outer surface 110. The base 204 of each spout 106 may be removeably coupled to a respective aperture 206. The lip 202 may be interconnected to the trough 112 via an aperture 208 extending through the spout 106 from the lip 202 to the base 204. While the surface of the aperture 208 is illustrated as being substantially void of dimples, bumps, ridges, etc. to provide a smooth surface, the surface of the aperture 208 may include surface features (e.g., grooves, fms, rifling, etc.) to provide a laminar flow of the molten metal 122 through the spouts 106. FIG. 2 illustrates the lip 202 of the spout 106 may be arranged radially 134 and may project from the outer surface 1 10 to pour the molten metal 122 into the respective molds 116.

[0037] As shown in detail view 210, each aperture 206 of the array of apertures 206 has a seat 212 arranged to receive the base 204 of each spout 106 of the plurality of spouts 106. An adhesive 214 may be disposed between the base 204 and the seat 212 to removeably couple the spout 106 to the aperture 206. For example, the adhesive 214 may be a mastic adhesive applied to the seat 212 and/or the base 204 and configured to be resistant to molten aluminum. Further, the adhesive 214 may be configured to fail (e.g., fracture, break, crack, crumble, etc.) upon impact of a sufficient force. For example, the plurality of spouts 106 may be removed by applying an impact or blow to the lip 202 of a spout 106. The blow or impact having sufficient force to cause the adhesive 214 adhering the seat 212 of the rim 104 to the base 204 of the spout 106 to fail allowing the spout 106 to be removed.

[0038] Detail view 210 illustrates the seats 212 may be arranged in the inner surface 108 of the rim 104. While the detail view 210 illustrates the base 204 of each spout 106 is substantially coplanar 216, the base 204 of each spout 106 may be below or above the inner surface 108 of the rim 104.

[0039] Detail view 210 illustrates the base 204 of each spout 106 and the seat 212 of each aperture may have a substantially conical shape 218. Further, the lip 202 of each spout 106 may have a substantially conical shape 220. While detail view 210 illustrates the lip 202 having a substantially conical shape 220, the lip 202 may have a substantially circular shaped, rectangular shaped, pyramidal shaped (e.g., tetrahedron, pentagonal, hexagonal, or the like pyramid shapes). For example, the shape of the spout 106 may be specific to a type of molten metal 122 being cast, a dispensing rate of molten metal 122, a speed of rotation of the casting wheel 102, a speed of the conveyor 114, the direction 118 of the conveyor 1 14 relative to the spouts 106 arranged on the casting wheel 102, combinations of any of these, or the like. In one example, the shape of the lip 202 of the spout 106 may be tailored to provide a laminar flow of molten metal 122 out of the spout 106 and into a respective permanent mold 116. For example, the lip 202 of the spout 106 may have an inside diameter 222 smaller than an inside diameter 224 of the base 204. The inside diameter 222 and/or 224 may be smaller than an inside diameter of a spout formed of metal. For example, the inside diameters 222 and/or 224 of the spout 106 may be smaller than an inside diameter of a metal spout to provide a slower filling rate of respective permanent molds 116 to produce a laminar flow of molten metal. In one example, the inside diameter 222 of the lip may be about 35 millimeters (1.3 inches), and the inside diameter 224 may be about 40 millimeters (1.6 inches). However, as discussed above the inside diameters 222 and 224 may be any size based on the type of molten metal 122 being cast, a dispensing rate of molten metal 122, a speed of rotation of the casting wheel 102, a speed of the conveyor 114, the direction 1 18 of the conveyor 1 14 relative to the spouts 106 arranged on the casting wheel 102, combinations of any of these, or the like. Further, the length of the spout 106 may be tailored to provide a laminar flow of molten metal 122 out of the spout 106 and into a respective permanent mold 116.

[0040] The plurality of spouts 106 removeably coupled to the rim 104 may be formed of the composite material. For example, the plurality of spouts 106 may be formed of ceramic. In one example, the plurality of spouts 106 may be formed of a fused silica. In another example, the plurality of spouts 106 may be formed of a fiberglass fabric embedded in a calcium silicate Ca₂Si0₄ slurry. However, the plurality of spouts 106 may be formed of any composite material suitable for being used to cast molten metal. Further, the plurality of spouts 106 may be formed of a metal. For example, the spouts may be formed of a cast iron, a steel, etc., and fixed to the rim 104. Further, the plurality of spouts 106 may be formed of a metal and at least partially encapsulated in a ceramic. For example, an inner body formed of an iron, a cast iron, a steel, etc., may be encapsulated by a ceramic to form a spout 106.

[0041] Further, the plurality spouts 106 may be permanently fixed to the rim 104. For example, the plurality of spouts 106 and the rim 104 may be formed as a single unit of a composite material. For example, the spouts 106 and the rim 104 may be formed as a single unit of fiberglass fabric embedded in calcium silicate Ca₂Si0₄ slurry. In another example, the plurality of spouts 106 may be formed of a ceramic (e.g., a fused silica) and fixed permanently to the rim 104, via a layer of the fiberglass fabric embedded in calcium silicate CaSi0₃ slurry. For example, subsequent to the base 204 of the spouts 106 being received by the seats 212 of the rim 104, the composite material (e.g., a fiberglass fabric embedded in a calcium silicate CaSi0₃ slurry) may be applied to the spouts 106 and the rim 104 to fix the spouts 106 to the rim 104.

[0042] Because the composite spouts 106 are formed of these ceramic materials, the plurality of spouts 106 provides properties suitable for casting molten aluminum. For example, the ceramic materials forming the plurality of spouts 106 insulate the molten aluminum being poured into the respective permanent molds 116. Thus, because the heat transfer rate from the molten aluminum to the spouts 106 is significantly reduced, the molten aluminum does not freeze or solidify on the spouts 106 as the casting wheel 102 dispenses the molten aluminum. Further, the ceramic materials forming the plurality of spouts 106 provide for a non-wetting surface. For example, the ceramic materials forming the plurality of spouts 106 may keep the molten aluminum from maintaining intermolecular interaction with the surface of the spouts 106. The non-wetting surface of the plurality of spouts 106 may prevent the molten aluminum from sticking to the surface of the spouts 106 and building up on the spouts 106 as the casting wheel 102 dispenses the molten aluminum. Further, because the ceramic materials forming the plurality of spouts 106 provide for preventing the molten aluminum from freezing on the spouts 106 and/or wetting and sticking to the spouts 106, it is easier to remove the frozen and/or stuck aluminum from the plurality of spouts 106 than compared to removing frozen and/or stuck aluminum from spouts formed of metal.

Example Methods of Installing Composite Casting Wheels

[0043] FIG. 3 illustrates an example process 300 of installing a casting wheel (e.g., casting wheel 102) at a casting facility. In example process 300, the casting wheel comprises a rim (e.g., rim 104) formed as a single unit (e.g., single unit 124) of a composite material (e.g., fabric embedded in ceramic). By way of example and not limitation, this process may be performed at a manufacturing facility, a plant, a foundry, a factory, or the like.

[0044] Process 300 includes operation 302, which represents positioning (e.g., lifting) the casting wheel adjacent to an axle. For example, a single user (e.g., operator, technician, workman) may single-handedly (i.e., without assistance from another user) position the casting wheel adjacent to the axle. Process 300 may be completed at operation 304, which represents fastening the casting wheel to the axle. For example, a user may insert one or more threaded fasteners (e.g., bolts) into an aperture (e.g., apertures 140) arranged in a wall (e.g., wall 142) of the casting wheel and into a mounting structure of the axle. Operation 304 may include tightening the one or more threaded fasteners (e.g., nuts) to secure the casting wheel to the axle.

[0045] FIG. 4 illustrates an example process 400 of installing a casting wheel (e.g., casting wheel 102) at a casting facility. In example process 400, the casting wheel comprises a rim (e.g., rim 104) formed from a plurality of segments (e.g., segments 128(1) through 128(N)) formed of a composite material (e.g., fabric embedded in ceramic). By way of example and not limitation, this process may be performed at a manufacturing facility, a plant, a foundry, a factory, or the like.

[0046] Process 400 includes operation 402, which represents positioning (e.g., lifting) at least one of the segments of the casting wheel adjacent to an axle. For example, a single user (e.g., operator, technician, workman) may single-handedly (i.e., without assistance from another user) position the segment adjacent to the axle. Operation 402 may be followed by operation 404, which represents fastening the at least one segment to the axle. For example, a user may insert one or more threaded fasteners (e.g., bolts) into an aperture (e.g., apertures 140) arranged in a wall (e.g., wall 142) of the segment and into a mounting structure of the axle. Operation 404 may include tightening the one or more threaded fasteners (e.g., nuts) to secure the segment to the axle. Process 400 may include operation 406, which represents positioning one or more additional segments of the casting wheel adjacent to the axle. Operation 406 may include interlocking the one or more additional segments together. For example, a user may interlock interlocking surfaces (e.g., interlocking surfaces 130(A) and 130(B)) to form the rim. Operation 406 may include fastening the one or more additional segments to the axle. For example, a user may insert one or more threaded fasteners (e.g., bolts) into apertures arranged in walls of the one or more additional segments and into a mounting structure of the axle.

[0047] Process 400 may include operation 408, which represents tightening a band (e.g., outer member 132) around the interlocked segments of the rim. Process 400 may be completed at operation 410, which represents tightening the one or more threaded fasteners (e.g., nuts) to secure the casting wheel to the axle.

Conclusion

[0048] Although the disclosure uses language specific to structural features and/or methodological acts, the claims are not limited to the specific features or acts described. Rather, the specific features and acts are disclosed as illustrative forms of implementing the invention. For example, the various embodiments described herein may be rearranged, modified, and/or combined. As another example, one or more of the method acts may be performed in different orders, combined, and/or omitted entirely, depending on the type of composite casting wheel to be installed in a particular casting facility.

Claims

WHAT IS CLAIMED IS:

1. A composite wheel for casting molten metal comprising:

a rim formed of a composite material, the rim comprising:

an inner surface opposite an outer surface, wherein the inner surface defines a trough to receive the molten metal; and

a plurality of spouts removeably coupled to the rim, wherein the plurality of spouts are interconnected with the trough, and arranged radially in the second surface to pour the molten metal into respective molds.

2. The composite wheel of claim 1, wherein the rim comprises a single unit of the composite material.

3. The composite wheel of claim 1 , wherein the rim comprises a plurality of segments formed of the composite material.

4. The composite wheel of claim 3, wherein each spout of the plurality of spouts is removeably coupled to a respective segment of the plurality of segments.

5. A casting wheel comprising:

a rim formed as a single unit of a composite material, the rim comprising: an inner surface opposite an outer surface, wherein the inner surface defines a trough to receive a molten metal; and a plurality of spouts removeably coupled to the rim, wherein the plurality of spouts are interconnected with the trough, and arranged radially in the second surface to pour the molten metal into respective molds.

6. The casting wheel of claim 5, wherein the composite material comprises a fabric embed in a ceramic.

7. The casting wheel of claim 6, wherein the fabric comprises a fiberglass and the ceramic comprises a calcium silicate.

8. The casting wheel of claim 5, wherein the plurality of spouts are removeably coupled to the rim via an adhesive.

9. The casting wheel of claim 5, wherein the plurality of spouts are formed of a composite.

10. The casting wheel of claim 9, wherein the composite comprises a ceramic.

1 1. The casting wheel of claim 10, wherein the ceramic comprises a fused silica.

12. A composite wheel for casting molten metal into respective molds, the composite wheel comprising:

a rim formed as a single unit of a composite material, the rim comprising: an inner surface opposite an outer surface, wherein the inner surface defines a trough to receive a molten metal;

an array of apertures arranged around the rim and extending through the inner surface and the outer surface; and

a plurality of spouts having a lip opposite a base, wherein the base is removeably coupled to the array of apertures, and the lip is interconnected to the trough and radially projects from the outer surface to pour the molten metal into the respective molds.

13. The composite wheel of claim 12, wherein the bases of the plurality of spouts are removeably coupled to the array of apertures via an adhesive.

14. The composite wheel of claim 12, wherein each aperture of the array of apertures has a seat arranged to receive the base of each spout of the plurality of spouts, and wherein an adhesive is disposed between the base and the seat.

15. The composite wheel of claim 14, wherein the seats are arranged in the inner surface of the rim.

16. The composite wheel of claim 15, wherein the base of each spout is at least below the inner surface of the rim to at most substantially coplanar with the inner surface of the rim.

17. The composite wheel of claim 14, wherein the adhesive comprises mastic adhesive.

18. The composite wheel of claim 12, wherein the base of each spout, and the seat of each aperture have a substantially conical shape.

19. The composite wheel of claim 12, wherein the lip of each spout has a substantially conical shape.

20. The composite wheel of claim 12, wherein the plurality of spouts have a degree of separation substantially the same as a distance between the respective molds.

21. A composite wheel for casting molten metal into respective molds, the composite wheel comprising:

a rim formed of a composite material, the rim comprising:

an inner surface opposite an outer surface, wherein the inner surface defines a trough to receive a molten metal;

a plurality of spouts having a lip opposite a base, and the lip is interconnected to the trough and radially projects from the outer surface to pour the molten metal into the respective molds.

22. The composite wheel of claim 21 , wherein the plurality of spouts and the rim are formed as a single unit of a composite material.

23. The composite wheel of claim 22, wherein the composite material comprises a fabric embed in a ceramic.

24. The composite wheel of claim 21, wherein the plurality of spouts are formed of a fused silica, the rim is formed as a single unit of a composite material, and the plurality of spouts are fixed to the rim via a layer of the composite material applied to the spouts and the rim.