Process for casting a metal

1. A process, for forming a metal casting by pouring molten metal into and around a casting assembly comprising an open riser having a cavity containing a sleeve, wherein said process comprises:

(a) inserting a riser insert into the cavity of the riser containing the sleeve, and

(b) then allowing molten metal to flow into the cavity of the riser containing the riser insert, wherein

the riser is shaped such that, or contains a barrier such that, the riser insert does not fall into other parts of the casting assembly before the molten metal is poured,

the density of the riser insert is such that the riser insert floats on the surface of the molten metal when the molten metal enters the cavity of the riser, and

the sleeve is shaped such that the sleeve holds the floating cover lid in place on top of the metal in the open riser after the molten metal is poured while excess metal is allowed to flow out of the top of the riser.

2. The process of claim 1 where the riser insert and/or sleeve act as barriers to heat loss from the metal in the riser by radiation and/or convection to the atmosphere.

3. The process of claim 2 wherein the riser insert and/or sleeve have insulating properties, exothermic properties, or both.

4. The process of claim 3 wherein the riser is a component of a casting assembly.

5. The process of claim 4 wherein the material used to make the riser insert and/or sleeve comprises hollow aluminosilicate microspheres.

6. The process of claim 5 where the riser contains a physical barrier to keep the riser insert in the riser and prevent the riser insert from falling out.

7. The process of claim 6 wherein the riser insert and/or sleeve are made by a cold-box process.

8. The process of claim 7 wherein the binder used in the cold-box process is a phenolic urethane binder and the catalyst is a vaporous tertiary amine catalyst.

9. The process of claim 8 wherein the riser contains a breaker core or is a neckdown riser.