Abstract: An apparatus for wax welding is provided that includes a removable cartridge adapted for operative engagement with a power supply. The removable cartridge includes a tube defining a proximal end portion, a distal end portion, a longitudinal axis, and a hollow bore, and a self-regulating heater is disposed within the tube. The apparatus further includes a tip secured to the distal end portion of the tube within the hollow bore, the tip defining a proximal end portion having an internal cavity. The tip defines an upper surface, a lower surface, and the tip is oriented relative to a longitudinal axis of the cartridge.

Abstract: A method of processing a casting is described. The method comprises removing a mold from a cast metal part without cold working surfaces of the cast metal part and thermally treating the cast metal part. The method can further comprise finishing the surfaces of the cast metal part after thermally treating such that any cold working of the surfaces of the cast metal part occurs after thermally treating such that no recast layer is formed in the cast metal part.

Abstract: Apparatus and method for purging atmospheric air from a chamber with a gas including means for generating a substantially non-turbulent, laminar flow front of the gas into the chamber with minimal turbulence to displace the atmospheric air in the chamber, the chamber having exhaust means associated therewith to permit the displaced atmospheric air to exit the chamber. The chamber is preferably a welding chamber and the gas is preferably argon.

Abstract: Methods of manufacturing castings are described. The method can include heating a ceramic mold having a gate inlet, and melting a metallic composition. The method can also include presenting the ceramic mold to a casting station such that the gate inlet is in fluid communication with the molten metallic composition, and casting against gravity the molten metallic composition into the heated mold through the gate inlet. Furthermore, the method can include rotating the mold to position with the gate inlet in an upward direction while the metallic composition is at least partially molten within the mold, and quenching the molten metallic composition in a liquid quench medium to solidify the molten metallic composition within the mold.

Abstract: A method of inspecting a part is provided that includes the steps of aligning a contoured sheet having at least one surface that corresponds to at least one surface of the part, the contoured sheet having first portions and second portions, the first portions being radiodense and the second portions being radiolucent, and at least some of the second portions corresponding to internal features of the part. The part with the contoured sheet is exposed to x-rays to produce a first radiograph with markings that correspond to the first and second portions of the contoured sheet.

Abstract: A template for radiography and methods of using and making a template are described. The template can include a contoured sheet having first portions and second portions. The first portions are radiodense and the second portions are radiolucent to provide markings on a radiograph. At least one surface of the contoured sheet can correspond to at least one surface of a target part to provide alignment of the contoured sheet to the target part.

Abstract: A tacking fastener for securing workpieces together to form a temporary assembly includes a stem and an elongated sleeve. The stem includes a head disposed at a proximal end portion, a tapered portion extending between the proximal end portion and a central portion, a break notch extending around a circumference of the proximal end portion between the head and the tapered portion, and a plurality of ridges and grooves disposed along a distal end portion. The elongated sleeve is disposed around the stem between the head and the plurality of ridges and grooves and configured to form a tacking rivet upon installation of the tacking fastener. The elongated sleeve is plastically deformed during installation to form a plurality of bulbs, thereby being capable of securing workpieces of varying grip length. The stem and the tacking rivet remain within the workpieces after the workpieces are secured.

Abstract: Methods of manufacturing castings are described. The method can include heating a ceramic mold comprising a gate inlet, and melting a metallic composition. The method can also include presenting the ceramic mold to a casting station such that the gate inlet is in fluid communication with the molten metallic composition, and casting against gravity the molten metallic composition into the heated mold through the gate inlet. Furthermore, the method can include rotating the mold to position with the gate inlet in an upward direction while the metallic composition is at least partially molten within the mold, and quenching the molten metallic composition in a liquid quench medium to solidify the molten metallic composition within the mold.

Abstract: A method of processing a casting is described. The method comprises removing a mold from a cast metal part without cold working surfaces of the cast metal part and thermally treating the cast metal part. The method can further comprise finishing the surfaces of the cast metal part after thermally treating such that any cold working of the surfaces of the cast metal part occurs after thermally treating such that no recast layer is formed in the cast metal part.

Abstract: Apparatus and method for purging atmospheric air from a chamber with a gas including means for generating a substantially non-turbulent, laminar flow front of the gas into the chamber with minimal turbulence to displace the atmospheric air in the chamber, the chamber having exhaust means associated therewith to permit the displaced atmospheric air to exit the chamber. The chamber is preferably a welding chamber and the gas is preferably argon.

Abstract: Apparatus and method for purging atmospheric air from a chamber with a gas including means for generating a substantially non-turbulent, laminar flow front of the gas into the chamber with minimal turbulence to displace the atmospheric air in the chamber, the chamber having exhaust means associated therewith to permit the displaced atmospheric air to exit the chamber. The chamber is preferably a welding chamber and the gas is preferably argon.

Abstract: Embodiments of a method for increasing the lifetime of a casting slurry are described. One feature of the disclosed embodiments comprises processing refractory materials that are used to form casting slurries to provide a substantial increase in slurry lifetime for slurries made using such processed materials compared to slurries made using materials not processed as described herein. One embodiment of the method comprises heat processing at least one refractory powder. Without limiting the invention to a theory of operation, processing is continued for a period of time sufficient to reduce the amount of hydration from a first hydration level to a second hydration level. A slurry is formed using the refractory powder at a hydration level which provides an increased slurry lifetime relative to the same material without processing according to the disclosed embodiments.

Abstract: An embodiment of a disclosed apparatus for sizing an engine stator has a plurality of radially moveable shoes for engaging the inner and outer rings of the stator. The shoes apply a radially directed force to the inner and outer rings to cause the rings to expand. In particular embodiments, one or more heating mechanisms, such as a ceramic heating blanket, may be used to heat the stator prior to sizing. A method for sizing an engine stator also is disclosed. The method comprises simultaneously displacing the inner and outer rings of the stator generally radially outwardly so as to increase the respective diameters of the inner and outer rings.

Abstract: An embodiment of a disclosed apparatus for sizing an engine stator has a plurality of radially moveable shoes for engaging the inner and outer rings of the stator. The shoes apply a radially directed force to the inner and outer rings to cause the rings to expand. In particular embodiments, one or more heating mechanisms, such as a ceramic heating blanket, may be used to heat the stator prior to sizing. A method for sizing an engine stator also is disclosed. The method comprises simultaneously displacing the inner and outer rings of the stator generally radially outwardly so as to increase the respective diameters of the inner and outer rings.

Abstract: The present disclosure describes improved compositions comprising an agitating agent, the compositions being particularly useful for powder injection molding. The disclosed method includes protocols for extracting binder materials from a powder injection molding prior to sintering. One embodiment of the disclosure includes compositions comprising a sinterable powder, a binder and a gas-forming agent. When induced to release a gas, the gas-forming agent provides internal agitation, which facilitates solvent-based binder extraction, resulting in a higher yield of extracted binder in reduced time. In one embodiment, the compositions include a carbonate, such as sodium carbonate, as the gas-forming agent. In this embodiment, the gas-forming agent is induced to form a gas during binder extraction by including an acid, such as citric acid, in the extraction solvent.

Abstract: Embodiments of a method for increasing the lifetime of a casting slurry are described. One feature of the disclosed embodiments comprises processing refractory materials that are used to form casting slurries to provide a substantial increase in slurry lifetime for slurries made using such processed materials compared to slurries made using materials not processed as described herein. One embodiment of the method comprises heat processing at least one refractory powder. Without limiting the invention to a theory of operation, processing is continued for a period of time sufficient to reduce the amount of hydration from a first hydration level to a second hydration level. A slurry is formed using the refractory powder at a hydration level which provides an increased slurry lifetime relative to the same material without processing according to the disclosed embodiments.

Abstract: Embodiment of a disclosed seam tool comprise a rigid backing configured to be positioned about a seam region defined by at least two adjacent pattern segments. The rigid backing further includes an injection port and, typically, a gas outlet port, fluidly coupled to the seam region. The disclosed device may further include a resilient liner which contacts and forms a seal with surfaces of the pattern segments. Compensating grooves may be formed in the resilient material to allow complete filling of the seam region by weld-forming material. An injection fitting may be operably coupled to an injection port to provide an improved ability to receive weld-forming material to form welds. A method for forming a weld between plural, adjacently positioned pattern segments also is disclosed. The method comprises positioning the disclosed embodiments of the seam tool about a seam region defined between adjacent pattern segments.

Abstract: A method for imaging inclusions in metal or metal alloy castings is described. One embodiment of the present method first involves casting a metal or metal alloy article using an investment casting mold where the mold facecoat, and perhaps one or more of the mold backup layers, comprises an imaging agent distributed substantially uniformly throughout in amounts sufficient for imaging inclusions. The facecoat preferably comprises an intimate mixture of a refractory material and the imaging agent. Intimate mixtures can be produced in a number of ways, but a currently preferred method is to cocalcine the refractory material, such as yttria, with the imaging agent, such as gadolinia. The facecoat also can comprise plural mold-forming materials and/or plural imaging agents. The difference between the linear attenuation coefficient of the article and the linear attenuation coefficient of the imaging agent should be sufficient to allow imaging of the inclusion throughout the article.

Abstract: A method for imaging inclusions in metal or metal alloy castings is described. One embodiment of the present method first involves casting a metal or metal alloy article using an investment casting mold where the mold facecoat, and perhaps one or more of the mold backup layers, comprises an imaging agent distributed substantially uniformly throughout in amounts sufficient for imaging inclusions. The facecoat preferably comprises an intimate mixture of a refractory material and the imaging agent. Intimate mixtures can be produced in a number of ways, but a currently preferred method is to cocalcine the refractory material, such as yttria, with the imaging agent, such as gadolinia. The facecoat also can comprise plural mold-forming materials and/or plural imaging agents. The difference between the linear attenuation coefficient of the article and the linear attenuation coefficient of the imaging agent should be sufficient to allow imaging of the inclusion throughout the article.

Abstract: Methods for increasing the lifetime of a casting slurry are described. One feature of the invention is processing refractory powders at a first hydration level to produce powders having a second, lower hydration level before the processed materials are used to form casting slurries. Processing according to the disclosed methods results in a substantial increase in the lifetime of a slurry made using such processed materials compared to slurries made using materials not processed as described herein. One embodiment of the method comprises heat processing at least one refractory powder, typically refractory powders which have undergone hydration subsequent to commercial production, for a period of time sufficient to reduce the amount of hydration from a first hydration level to a second hydration level. A slurry is formed using the refractory powder at an hydration level which provides an increased slurry lifetime relative to the same material without processing according to the method of the present invention.