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US3847715A - Decorative castings and method of fabrication thereof - Google Patents

Decorative castings and method of fabrication thereof Download PDF

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US3847715A
US3847715A US00362930A US36293073A US3847715A US 3847715 A US3847715 A US 3847715A US 00362930 A US00362930 A US 00362930A US 36293073 A US36293073 A US 36293073A US 3847715 A US3847715 A US 3847715A
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ice
casting
bed
molten metal
pieces
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R Goodspeed
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Teledyne Inc
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Teledyne Inc
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B44DECORATIVE ARTS
    • B44CPRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
    • B44C3/00Processes, not specifically provided for elsewhere, for producing ornamental structures
    • B44C3/04Modelling plastic materials, e.g. clay
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/12All metal or with adjacent metals
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/12All metal or with adjacent metals
    • Y10T428/12993Surface feature [e.g., rough, mirror]

Definitions

  • ABSTRACT [52] US. Cl 161/7, 164/76, 164/138, A method f ing. m al whereby unique decora- 249/62 264/317 tive objects may be obtained.
  • the method is com- [51] Int. Cl 322d 25/02 prised of p ding a d of ice of proper character [58] Field of Search 164/138, 76, 78, 79; and p g molten m ta f a contr ll d temperature 249/61, 62; 161/7; 264/317 over the ice.
  • Prior Art Objects of art and decoration have been fabricated by ordinary metal casting techniques for a great number of years. Such objects of decoration are casts using a prepared pattern so that each casting is a duplication of a set pattern. Typically, a considerable amount of finishing work is required to complete the objects, as the cast surface is generally not as desired for the finished item. Further, only shapes which allow the removal of a pattern (or the removal of the finished object from the molds if processes such as die casting are used) may be cast, thereby highly limiting the character and appearance of the finished item. Further, since each item is a reproduction of the pattern used, the copies have no individual character, and any change may involve considerable expense in making a new pattern therefor.
  • Some interesting forms for decorative purposes have been created by pouring a molten metal, typically aluminum, onto a relatively flat surface, allowing the metal to splash and solidify in a relatively random form.
  • Such techniques yield a different result for each article formed in that manner and provide many interesting flowing forms and shapes in the finished product.
  • the form created in this manner must necessarily be relatively thin and flat and therefore is generally usable only as a wall decoration and the like, as opposed to a true, three-dimensional object of art for display in a cabinet, on a coffee table, etc., or for formation of such other particles as candlestick holders and the like.
  • the article formed in this manner may have an undesired surface finish, and generally has sharp points and edges which must be removed in order to prevent injury to a person touching the article and to provide the desired visual results.
  • a method of casting metals whereby unique decorative objects may be obtained.
  • the method is comprised of providing a bed of ice, preferably free of frost, and pouring molten metal of a controlled temperature over the ice in a smooth but rapid manner.
  • the bed of ice preferably is of random sized pieces of ice having rounded corners and contours and having a maximum size which is reasonably small in comparison with the intended casting to be made therefrom.
  • Most metals may be used for forming castings in accordance with the invention, with the metals generally being selected based on considerations of cost, ease of finishing and environmental integrity.
  • Finishes include painting by dip or spray processes, including electrostatic painting, and special finishes, suchas colored anodize in the case of aluminum castings, may be used to provide startling finishes for the castings. Methods for providing openings or pockets in the finished castings are described, as are other variations in the invention.
  • FIG. 1 is a side view of a typical work of art formed by the present invention casting method.
  • FIG. 2 is the perspective view of a typical ice bed, which may be used in accordance with the present invention method.
  • FIG. 3 is a cross section of the apparatus of FIG. 2, illustrating the use of a plug in the ice bed and the manner in which the molten metal is poured thereover.
  • FIG. 4 is a side view of a fixture suitable for use. in providing an appropriate base surface forcastings having an opening therethrough, defined during casting by the plug shown in FIGS. 2- and 3.
  • FIG. 1 a side view of an ornamental work of art which may be fabricated in accordance subsequently described in greater detail, the size, height, etc., of the casting, the flatness of the base and other general characteristics may be readily controlled by controlling various parameters in the casting method to result in castings of a great variety of size and character.
  • a container 24, open at the top is provided with a valve 28 at the base thereof for allowing the drainage of water from the container.
  • the chunks of ice 26 are preferably approximately the size of normal ice cubes, and in fact for this purpose standard ice cubes may be used.
  • thechunks of ice will be stored within a refrigerating means prior to use. Accordingly, the ice will normally be at a temperature substantially below the freezing point, and will frost over when exposed to the normal foundry environment. It has been found that the accumulation of frost on the ice may detract from the desired visual appearance of the resulting casting, and accordingly in the preferred method of practicing the present invention, the frost is first removed by spraying the ice lightly with water by a hose 30. The spraying not only quickly removes the frost, but further tends to increase the temperature of the ice to the freezing point, so that further formation of frost is greatly retarded. The spraying has a still further advantage in that it induces melting of sharp edges and corners on the chunks of ice 26, giving them a less geometrical shape which, as shall subsequently become apparent, improves the visual appearance of the resulting casting.
  • molten metal such as aluminum of an appropriate temperature may be poured onto the ice and allowed to solidify as it runs between the chunks of ice.
  • an appropriate member to define the opening such as the aluminum plug 32 (shown in FIGS. 2 and 3) may be disposed within the ice as shown.
  • the plug 32 may rest on the bottom of the container 24, though this is not required, and in fact is preferably readily removable so that after casting, the bed of ice may be replenished and new chunks of ice randomly mixed with those remaining after the previous casting.
  • the plug 32 should extend upward above the top surface of the ice and have a concave upper surface, such as the spherical section 34 so as to avoid the retention of molten metal thereon.
  • molten metal may be poured around the top of the plug 32 so as to be fairly uniformly distributed around the periphery of the plug.
  • the metal 36 may be poured using a ladle 38, and should be poured quickly but smoothly, almost as if dumping a glob of molten metal around the plub 32.
  • the metal quickly runs down between the chunks of ice 26 in a random manner (partially melting them) before solidifying, resulting in a casting created by the random flow paths, sizes and shapes of the ice, just prior to solidifying.
  • chunks of ice are of random size and at least having rounded corners are used.
  • a wide range of casting sizes may be made in accordance with the present invention by merely increasing the amount of metal poured over the ice.
  • the size of the chunks of ice themselves for larger castings should in general be increased, though differences in visual appearance and character of castings of the same size may be made by varying the size of the chunks of ice within a reasonable range.
  • the resulting castings are each unique in appearance, and equally importantly are substantially free of sharp protrusions so that very little handwork is required after casting to remove these hazards. Instead, the castings are an attractive blend of random shaped, enlarged areas and thin contoured sections, all of which appear connected by a plurality of edges of varying radius, but nowhere being significantly sharp to present a hazard to a person handling the castmg.
  • Another parameter which may be varied to vary the effect achieved is the temperature of the molten metal used.
  • the higher the temperature the more the metal tends to run between the chunks of ice before solidifying, so that a taller, perhaps more open type of decorative casting is achieved.
  • the hotter the metal the more tendency there is for spikes and sharp protrusions to form, so that temperature control of the molten metal provides a control on these hazards.
  • the temperature of the metal is too low, solidification of the metal will occur before it has sufficient opportunity to flow between the chunks of ice and form what will appear to be the stalagmite type extensions in the finished casting.
  • the particular alloy used By way of example, in the case of aluminum, relatively pure aluminum solidifies at one particular temperature whereas alloys solidify over a temperature range.
  • the top surface thereof will become the base on which the casting will ultimately rest. Accordingly, this top surface characteristically is very irregular, being defined by the irregular surface of the ice bed. However, normally there will be three areas which are higher than other areas so that the casting will naturally tend to stay on these areas. In fact, for many castings of a purely decorative character, the castings will naturally stand in any of a plurality of positions, each of which yields a substantially different visual appearance of the casting because of the different perspective, which in itself is a desirable result.
  • a plug such as plug 32
  • a fixture such as is shown in FIG. 4 for the case of a vertical plug may be used to align the base of the casting with the opening therethrough.
  • the fixture is characterized by a metal plug 40 similar to plug 32 mounted on a heavy metal base 42. The casting is then placed over the plug 40 and slammed down onto base 42 so as to align the high points on the base in a plane perpendicular to the opening through the casting defined by the plug 32.
  • the high points on the base are relatively thin so as to be reasonably easily leveled in this manner immediately after being removed from the ice bed and inspected for any sharp protrusions-
  • the tank containing the ice bed may also be partially or substantially filled with water. While the resulting casting may have a number of sharp protrusions, the artistic character of the resulting casting is far superior to those cast in water without the ice, as the ice distributes the metal quite evenly and prevents the sinking and solidification of the metal in large blobs.
  • a somewhat elongate casting may be achieved by pouring along a line in the center of the ice bed or, if a generally flat back surface of the casting is desired, by pouring along the edge of the container holding the ice so that the random flow of the metal is limited in that direction.
  • multi-colored castings may be created by such processes as spraying the castings from two directions using different colored paints.
  • Other variations may be created by utilizing different size and character ice at different positions in the ice bed.
  • variations in size with vertical position in the ice bed, variations in horizontal directions, or threedimensional variations in the character of the ice bed might be utilized.
  • a method of casting decorative items comprising the steps of preparing a bed of pieces of ice, pouring molten metal onto said bed, and allowing said molten metal to solidify as it runs between said pieces of ice.
  • a method of casting decorative items comprising:
  • said solid object is a metal member having a convex top disposed so as to protrude above the top surface of said bed of ice, and said molten metal is poured generally over said metal member whereby said metal member may subsequently be removed from said casting, thereby defining an opening of a predetermined shape in said casting.
  • Themethod of claim 9 including the further steps of locating said casting with respect to the opening defined by metal member and striking the bottom of said casting on a surface approximately perpendicular to said opening to flatten said bottom.
  • An object of art and decoration manufactured by preparing a bed of pieces of ice, pouring molten metal onto said bed, and allowing said molten metal to solidify as it runs between said pieces of ice.
  • An object of art and decoration manufactured by a. preparing a bed of pieces of ice; b. pouring molten metal of a predetermined temperature onto said bed of ice;

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  • Dispersion Chemistry (AREA)
  • Fencing (AREA)

Abstract

A method of casting metals whereby unique decorative objects may be obtained. The method is comprised of providing a bed of ice of proper character and pouring molten metal of a controlled temperature over the ice. Various results and ornamental characteristics may be achieved by variations and/or additions to the method as well as in the various finishes to the cast article which may be applied.

Description

lJnit ed States Patent 1191 Goodspeed Nov. 12, 1974 DECORATIVE CASTINGS AND METHOD 3,738,417 6/1973 Moore 164 76 OF FABRICATION THEREOF FOREIGN PATENTS OR APPLICATIONS lnventofi Raymflnd E- Goodspeed, Garden 41,790 4/1910 Austria 249/62 Grove, Cal1f. 1,580,370 9/1969 France 249/62 [73] Assignee: Teledyne, Inc., d/b/a Teledyne Casting Los Angeles Calif Primary ExammerR0bert D. Baldwm Assistant Examiner-John E. Roethel [22] Flled: May 1973 Attorney, Agent, or FirmSpensley, Horn & Lubitz [2]] Appl. No.: 362,930
[57] ABSTRACT [52] US. Cl 161/7, 164/76, 164/138, A method f ing. m al whereby unique decora- 249/62 264/317 tive objects may be obtained. The method is com- [51] Int. Cl 322d 25/02 prised of p ding a d of ice of proper character [58] Field of Search 164/138, 76, 78, 79; and p g molten m ta f a contr ll d temperature 249/61, 62; 161/7; 264/317 over the ice. Various results and ornamental characteristics may be achieved by variations and/or addi- [56] Ref n es Cit d tions to the method as well as in the various finishes to the cast article may be 393,954 12/1888 Woodward 164/79 X 13 Claims, 4 Drawing Figures DECORATIVE CASTINGS AND METHOD OF FABRICATION THEREOF BACKGROUND OF THE INVENTION 1. Field of the Invention This invention relates to the field of casting, and more particularly to the casting of objects of art and decoration.
2. Prior Art Objects of art and decoration have been fabricated by ordinary metal casting techniques for a great number of years. Such objects of decoration are casts using a prepared pattern so that each casting is a duplication of a set pattern. Typically, a considerable amount of finishing work is required to complete the objects, as the cast surface is generally not as desired for the finished item. Further, only shapes which allow the removal of a pattern (or the removal of the finished object from the molds if processes such as die casting are used) may be cast, thereby highly limiting the character and appearance of the finished item. Further, since each item is a reproduction of the pattern used, the copies have no individual character, and any change may involve considerable expense in making a new pattern therefor. In recent years there has been a growing interest in free form art objects, that is art objects having a natural appearance, pleasing in form and contour without being, functional in appearance. Preferably such items should each have an individual character, thereby making each an original work of art. Normal casting methods are not conducive to the production of such items, as the most pleasant shapes and forms as well as variations from one casting to another are impossible to achieve with conventional casting tech-- niques.
Some interesting forms for decorative purposes have been created by pouring a molten metal, typically aluminum, onto a relatively flat surface, allowing the metal to splash and solidify in a relatively random form. Such techniques yield a different result for each article formed in that manner and provide many interesting flowing forms and shapes in the finished product. However, the form created in this manner must necessarily be relatively thin and flat and therefore is generally usable only as a wall decoration and the like, as opposed to a true, three-dimensional object of art for display in a cabinet, on a coffee table, etc., or for formation of such other particles as candlestick holders and the like. Also, the article formed in this manner may have an undesired surface finish, and generally has sharp points and edges which must be removed in order to prevent injury to a person touching the article and to provide the desired visual results.
v There is a very substantial market for objects of art having varying three-dimensional characteristics, provided such objects may be relatively inexpensively fabricated and provided with various finishes and physical characteristics to. provide the desired uniqueness in each and every article made. Recognizing this need, various attempts have been made to directly cast such articles utilizing various molten metals. One method .which has been attempted is to pour molten metal into water hoping that the random pattern or form taken by the metal as it is sinking, but before solidifying, will provide the desired decorative character in the solidified object. This method, however, is unsatisfactory since the violent boiling and exhausting of steam renders the process generally uncontrollable, and any finished object which has a pleasing appearance also has a large plurality of very finely pointed spires and sharp edges, requiring excessive finishing work to render the object safe to the touch. In any event, attempting to pour molten metal such as aluminum and the like into water is at best dangerous because of the violence caused by the rapid expulsion of heat stored in the molten metal as steam as the metal contacts the water. In this regard, it should be noted that many persons have been injured or killed in foundries as a result of the literal explosion occurring when hot objects, such as molten metal, ladles, etc. contact water, whether within or without a mold cavity.
There is therefore a need for a casting method which may be used to yield artistic castings of varied character and requiring a minimum of finishing to provide a pleasing and attractive three-dimensional work of art of unique character.
BRIEF SUMMARY OF THE INVENTION A method of casting metals whereby unique decorative objects may be obtained. The method is comprised of providing a bed of ice, preferably free of frost, and pouring molten metal of a controlled temperature over the ice in a smooth but rapid manner. The bed of ice preferably is of random sized pieces of ice having rounded corners and contours and having a maximum size which is reasonably small in comparison with the intended casting to be made therefrom. Most metals may be used for forming castings in accordance with the invention, with the metals generally being selected based on considerations of cost, ease of finishing and environmental integrity. Finishes include painting by dip or spray processes, including electrostatic painting, and special finishes, suchas colored anodize in the case of aluminum castings, may be used to provide startling finishes for the castings. Methods for providing openings or pockets in the finished castings are described, as are other variations in the invention.
BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a side view of a typical work of art formed by the present invention casting method.
FIG. 2 is the perspective view of a typical ice bed, which may be used in accordance with the present invention method.
FIG. 3 is a cross section of the apparatus of FIG. 2, illustrating the use of a plug in the ice bed and the manner in which the molten metal is poured thereover.
FIG. 4 is a side view of a fixture suitable for use. in providing an appropriate base surface forcastings having an opening therethrough, defined during casting by the plug shown in FIGS. 2- and 3.
DETAILED DESCRIPTION OF THE INVENTION First referring to FIG. 1, a side view of an ornamental work of art which may be fabricated in accordance subsequently described in greater detail, the size, height, etc., of the casting, the flatness of the base and other general characteristics may be readily controlled by controlling various parameters in the casting method to result in castings of a great variety of size and character.
In the description to follow, the preferred method of forming a casting of the type shown in FIG. 1 of an artistic and ornamental character shall be described in detail. It is to be understood, however, that this specific description is made for purposes of explanation only and that certain steps are included only because they result in improved surface characteristics or yield certain specific results not essential to the successful practice of theinvented method, and that various changes in the methods and apparatus may be made by those skilled in the art to achieve castings of somewhat different visual and physical characteristics. Thus, in accordance with the preferred method, a container 24, open at the top is provided with a valve 28 at the base thereof for allowing the drainage of water from the container. The container 24, which should be capable of withstanding relatively high temperatures, at least for short periods as may be encountered from splashing molten metal, etc., is filled with chunks of ice 26. For a decorative casting suitable for display on a table, the chunks of ice 26 are preferably approximately the size of normal ice cubes, and in fact for this purpose standard ice cubes may be used.
In a normal casting environment, thechunks of ice, whether conventional ice cubes or crushed ice of selected size, will be stored within a refrigerating means prior to use. Accordingly, the ice will normally be at a temperature substantially below the freezing point, and will frost over when exposed to the normal foundry environment. It has been found that the accumulation of frost on the ice may detract from the desired visual appearance of the resulting casting, and accordingly in the preferred method of practicing the present invention, the frost is first removed by spraying the ice lightly with water by a hose 30. The spraying not only quickly removes the frost, but further tends to increase the temperature of the ice to the freezing point, so that further formation of frost is greatly retarded. The spraying has a still further advantage in that it induces melting of sharp edges and corners on the chunks of ice 26, giving them a less geometrical shape which, as shall subsequently become apparent, improves the visual appearance of the resulting casting.
If a simple art object is desired, molten metal such as aluminum of an appropriate temperature may be poured onto the ice and allowed to solidify as it runs between the chunks of ice. If, however, an object such as, by way of example, a large candlestick holder is being cast and a controlled opening or pocket is desired in the resulting casting, an appropriate member to define the opening, such as the aluminum plug 32 (shown in FIGS. 2 and 3) may be disposed within the ice as shown. The plug 32 may rest on the bottom of the container 24, though this is not required, and in fact is preferably readily removable so that after casting, the bed of ice may be replenished and new chunks of ice randomly mixed with those remaining after the previous casting. Assuming that the opening is to pass all theway through the finished casting, the plug 32 should extend upward above the top surface of the ice and have a concave upper surface, such as the spherical section 34 so as to avoid the retention of molten metal thereon.
With the plug 32 in position, molten metal may be poured around the top of the plug 32 so as to be fairly uniformly distributed around the periphery of the plug. The metal 36 may be poured using a ladle 38, and should be poured quickly but smoothly, almost as if dumping a glob of molten metal around the plub 32. The metal quickly runs down between the chunks of ice 26 in a random manner (partially melting them) before solidifying, resulting in a casting created by the random flow paths, sizes and shapes of the ice, just prior to solidifying.
As previously mentioned, better visual characteristics in the finished casting will be obtained if chunks of ice are of random size and at least having rounded corners are used. Obviously, a wide range of casting sizes may be made in accordance with the present invention by merely increasing the amount of metal poured over the ice. Similarly, the size of the chunks of ice themselves for larger castings, should in general be increased, though differences in visual appearance and character of castings of the same size may be made by varying the size of the chunks of ice within a reasonable range.
One of the principal advantages of the present invention method is that the resulting castings are each unique in appearance, and equally importantly are substantially free of sharp protrusions so that very little handwork is required after casting to remove these hazards. Instead, the castings are an attractive blend of random shaped, enlarged areas and thin contoured sections, all of which appear connected by a plurality of edges of varying radius, but nowhere being significantly sharp to present a hazard to a person handling the castmg.
Another parameter which may be varied to vary the effect achieved is the temperature of the molten metal used. In general, the higher the temperature, the more the metal tends to run between the chunks of ice before solidifying, so that a taller, perhaps more open type of decorative casting is achieved. Also, the hotter the metal the more tendency there is for spikes and sharp protrusions to form, so that temperature control of the molten metal provides a control on these hazards. Similarly, if the temperature of the metal is too low, solidification of the metal will occur before it has sufficient opportunity to flow between the chunks of ice and form what will appear to be the stalagmite type extensions in the finished casting. Also of significance is the particular alloy used. By way of example, in the case of aluminum, relatively pure aluminum solidifies at one particular temperature whereas alloys solidify over a temperature range. These characteristics all effect the preferred pouring temperature and to some degree effect the characteristics of the finished casting.
As the solidified casting lies in the bed of ice the top surface thereof will become the base on which the casting will ultimately rest. Accordingly, this top surface characteristically is very irregular, being defined by the irregular surface of the ice bed. However, normally there will be three areas which are higher than other areas so that the casting will naturally tend to stay on these areas. In fact, for many castings of a purely decorative character, the castings will naturally stand in any of a plurality of positions, each of which yields a substantially different visual appearance of the casting because of the different perspective, which in itself is a desirable result. In the case of castings to be used for candlestick holders and the like, wherein a plug such as plug 32 is used during the casting process, it is usually desired to have the opening defined by the plug 32 perpendicular to the base of the casting (or other desired orientation as non-vertical plugs may also be used). In such cases, a fixture such as is shown in FIG. 4 for the case of a vertical plug may be used to align the base of the casting with the opening therethrough. The fixture is characterized by a metal plug 40 similar to plug 32 mounted on a heavy metal base 42. The casting is then placed over the plug 40 and slammed down onto base 42 so as to align the high points on the base in a plane perpendicular to the opening through the casting defined by the plug 32. In this regard, the high points on the base are relatively thin so as to be reasonably easily leveled in this manner immediately after being removed from the ice bed and inspected for any sharp protrusions- As a further alternate method, the tank containing the ice bed may also be partially or substantially filled with water. While the resulting casting may have a number of sharp protrusions, the artistic character of the resulting casting is far superior to those cast in water without the ice, as the ice distributes the metal quite evenly and prevents the sinking and solidification of the metal in large blobs.
Various finishes may be applied to the castings. By way of example, it has been found that spray painting shot from different directions covers the castings well in spite of the large number .of cavities, concave surfaces, etc. Similarly, dip painting has also been used, though in general spray painting has been found to provide better results. However, painting generally tends to detract from the unusual character of the casting surface itself. Consequently, finishing processes such as anodizing, using colored anodize by way of example, have been found most successful, resulitng in an unusually attractive finish and exhibiting the full range of surface characteristics existing in the unfinished casting itself. In this regard, surface finish as well as the alloy used will depend somewhat on the intended purpose of the casting. Because of the random, irregular, yet smooth and generally open character of the casting, they are very suitable for use as decorations on the bottom of an aquarium. Consequently, a noncorroding alloy and a non-toxic finish should be used for castings of this intended purpose. By way of example, aluminum having a purity of at least 99.9 percent with a colored anodize surface has been found appropriate for such uses. Also, it should be noted that while the method described herein contemplated the pouring of the molten metal generally at the center of an ice bed with or without one or more plugs to define openings or cavities therein, a somewhat elongate casting may be achieved by pouring along a line in the center of the ice bed or, if a generally flat back surface of the casting is desired, by pouring along the edge of the container holding the ice so that the random flow of the metal is limited in that direction.
There has been described herein methods of casting objects of art and for providing the desired surface finish and color thereon. lt isto be understood however, that while the foregoing explanation, described in detail for the preferred method and materials such as aluminum, the present invention may be practiced with other metals, such as, by way of example, zinc, brass and stainless steel, to name a few. Further, the size of the casting which may be made in accordance with the present invention is limited primarily by the size of the ice bed and the quantity of molten metal which may be rapidly delivered to the ice bed for the casting. Of course, the nature of the finish required or desired will vary depending upon the material, with certain materials such as stainless steel providing an attractive product without any special surface coating. In other cases multi-colored castings may be created by such processes as spraying the castings from two directions using different colored paints. Other variations may be created by utilizing different size and character ice at different positions in the ice bed. By way of example, variations in size with vertical position in the ice bed, variations in horizontal directions, or threedimensional variations in the character of the ice bed might be utilized. Thus, while the invention has been particularly shown and described with reference to the preferred methods thereof, it will be understood by those skilled in the art that various changes in detail may be made therein without departing from the spirit and scope of the invention.
I claim:
1. A method of casting decorative items comprising the steps of preparing a bed of pieces of ice, pouring molten metal onto said bed, and allowing said molten metal to solidify as it runs between said pieces of ice.
2. The method of claim 1 wherein said ice is rinsed with water to remove frost therefrom prior to pouring said molten metal.
3. The method of claim 1 wherein said metal is aluminum, and further comprising the step of anodizing said aluminum after casting. 1
4. The method of claim 1 wherein said item is painted after casting.
5. The method of claim 1 wherein said pieces of ice are ice cubes.
6. The method of claim 1 wherein said pieces of ice are a combination of ice cubes and portions thereof remaining after the casting of previous items.
7. A method of casting decorative items comprising:
a. preparing a bed of pieces of ice;
b. pouring molten metal of a predetermined temperature onto said bed of ice;
c. allowing said molten metal to solidify to form a casting as it runs between said pieces of ice;
d. removing said casting from said bed of ice.
8. The method of claim 7 wherein at least one solid object of a predetermined shape is disposed in said bed of ice and the molten metal is poured at least adjacent said solid object.
9. The method of claim 8 wherein said solid object is a metal member having a convex top disposed so as to protrude above the top surface of said bed of ice, and said molten metal is poured generally over said metal member whereby said metal member may subsequently be removed from said casting, thereby defining an opening of a predetermined shape in said casting.
l0. Themethod of claim 9 including the further steps of locating said casting with respect to the opening defined by metal member and striking the bottom of said casting on a surface approximately perpendicular to said opening to flatten said bottom.
11. An object of art and decoration manufactured by preparing a bed of pieces of ice, pouring molten metal onto said bed, and allowing said molten metal to solidify as it runs between said pieces of ice.
12. An object of art and decoration manufactured by a. preparing a bed of pieces of ice; b. pouring molten metal of a predetermined temperature onto said bed of ice;
odize finish.

Claims (13)

1. A method of casting decorative items comprising the steps of preparing a bed of pieces of ice, pouring molten metal onto said bed, and allowing said molten metal to solidify as it runs between said pieces of ice.
2. The method of claim 1 wherein said ice is rinsed with water to remove frost therefrom prior to pouring said molten metal.
3. The method of claim 1 wherein said metal is aluminum, and further comprising the step of anodizing said aluminum after casting.
4. The method of claim 1 wherein said item is painted after casting.
5. The method of claim 1 whereiN said pieces of ice are ice cubes.
6. The method of claim 1 wherein said pieces of ice are a combination of ice cubes and portions thereof remaining after the casting of previous items.
7. A method of casting decorative items comprising: a. preparing a bed of pieces of ice; b. pouring molten metal of a predetermined temperature onto said bed of ice; c. allowing said molten metal to solidify to form a casting as it runs between said pieces of ice; d. removing said casting from said bed of ice.
8. The method of claim 7 wherein at least one solid object of a predetermined shape is disposed in said bed of ice and the molten metal is poured at least adjacent said solid object.
9. The method of claim 8 wherein said solid object is a metal member having a convex top disposed so as to protrude above the top surface of said bed of ice, and said molten metal is poured generally over said metal member whereby said metal member may subsequently be removed from said casting, thereby defining an opening of a predetermined shape in said casting.
10. The method of claim 9 including the further steps of locating said casting with respect to the opening defined by metal member and striking the bottom of said casting on a surface approximately perpendicular to said opening to flatten said bottom.
11. An object of art and decoration manufactured by preparing a bed of pieces of ice, pouring molten metal onto said bed, and allowing said molten metal to solidify as it runs between said pieces of ice.
12. An object of art and decoration manufactured by a. preparing a bed of pieces of ice; b. pouring molten metal of a predetermined temperature onto said bed of ice; c. allowing said molten metal to solidify to form a casting as it runs between said pieces of ice; d. removing said casting from said bed of ice; e. providing a decorative finish on said casting.
13. The object of claim 12 wherein said metal and object are aluminum and said decorative finish is an anodize finish.
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Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0042328A1 (en) * 1980-06-13 1981-12-23 Claude Victor Boeltz Foundry process
US5853825A (en) * 1996-05-08 1998-12-29 Parsons; Donald Homer Free form nugget and method of casting
US6132821A (en) * 1998-09-24 2000-10-17 Garr; Dan A. Sculpted wall adornment
CN101734079B (en) * 2008-11-05 2013-02-27 朱军岷 Dieless controllable metal fusion cast molding method
USD776856S1 (en) 2015-11-06 2017-01-17 Bocci Design and Manufacturing, Inc. Pendant lamp

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Publication number Priority date Publication date Assignee Title
US393954A (en) * 1888-12-04 Method of producing electrodes for secondary batteries
AT41790B (en) * 1909-03-15 1910-04-11 Anton Endler Process for the production of cavities in ceilings and the like from artificial stone.
FR1580370A (en) * 1968-07-01 1969-09-05
US3738417A (en) * 1971-05-24 1973-06-12 N Moore Metal art forms and method for producing the same

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US393954A (en) * 1888-12-04 Method of producing electrodes for secondary batteries
AT41790B (en) * 1909-03-15 1910-04-11 Anton Endler Process for the production of cavities in ceilings and the like from artificial stone.
FR1580370A (en) * 1968-07-01 1969-09-05
US3738417A (en) * 1971-05-24 1973-06-12 N Moore Metal art forms and method for producing the same

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0042328A1 (en) * 1980-06-13 1981-12-23 Claude Victor Boeltz Foundry process
US5853825A (en) * 1996-05-08 1998-12-29 Parsons; Donald Homer Free form nugget and method of casting
US6132821A (en) * 1998-09-24 2000-10-17 Garr; Dan A. Sculpted wall adornment
CN101734079B (en) * 2008-11-05 2013-02-27 朱军岷 Dieless controllable metal fusion cast molding method
USD776856S1 (en) 2015-11-06 2017-01-17 Bocci Design and Manufacturing, Inc. Pendant lamp

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