Abstract: A system for creating an interlock feature between two related railcar coupler cores comprises a first half of a corebox defining cavity for forming a first half of a railcar coupler core, a second half of a corebox defining a cavity for forming second half of a railcar coupler core, and a loose piece loose piece including an extension on a first side shaped to fit in the cavities.

Abstract: A core assembly for creating interior spaces in a railcar coupler knuckle is designed to be set in a cavity with cope and drag sections. The cavity is shaped to form a railcar coupler knuckle and includes a first wall that forms the substantially vertical outside wall of the tail of the knuckle. The core includes a kidney section with a rear core support section that extends at least 0.5? outside the first wall of the cavity when the core is set in the drag.

Abstract: A method for manufacturing a railcar coupler knuckle, said method includes providing a cope mold portion and a drag mold portion. The cope and drag mold portions have internal walls that define at least in part perimeter boundaries of a coupler knuckle mold cavity. At least one chill core is positioned within one of the cope mold portion and the drag mold portion. The cope and drag mold portions are closed, with the at least one core therebetween, and the closed cope and drag mold portions and the chill core define a parting line. The mold cavity is filled with a molten metal, which solidifies after filling to form a casting. The casting includes a pulling face portion defined by the chill core, and a central section of the pulling face portion does not contain the parting line and requires no finish grinding upon its formation.

Abstract: A railroad coupler assembly having at least a body and a knuckle both formed in a no-bake manufacturing process, the body and the knuckle having dimensional tolerances of distances between features that wear during operation that are about half those obtained from a body and a knuckle manufactured by a green sand process, resulting in increased fatigue life compared to the body and the knuckle manufactured by a green sand process.

Abstract: A coupler body for a railcar coupler, said coupler body comprising at least one central datum feature that does not wear during coupler use.

Abstract: A finger core for forming the front part of a knuckle for a railcar, said finger core comprising a single opening to form a single rib at the horizontal center line of the resulting knuckle.

Abstract: A method of manufacturing an enclosed railcar comprising the steps of providing a railcar, the railcar having at least a car deck, two side sills and two end sills, attaching a superstructure enclosure having at least one width extending bottom side chord along the two side sills of the railcar, wherein the superstructure is wider than the width of the railcar, and attaching a plurality of gussets to a side sill and an underside of at least one width extending bottom side chord.

Abstract: A method of manufacturing a railcar having an enclosing superstructure which is capable of accommodating large vehicles such as semi-trucks is disclosed. The method includes the preparation of a previously used railcar or a railcar originally manufactured for another purpose and the subsequent attachment of a preferably widened superstructure applied thereto. Usable space and dimensions within the superstructure enclosure are maximized by the use of shallow weight bearing side structures, large top chords, stabilizing door headers, an extension of the railcar deck and thin end doors. Railcar accessories are accommodated within the interior of the superstructure such that minimal useful space is used.