Abstract: A method for die casting a hybrid component includes defining a cavity within a die element of a die and inserting a spar into the cavity. Molten metal is injected into the die element. The molten metal is solidified within the cavity to cast the hybrid component. The spar establishes an internal structure of the hybrid component. The spar includes a high melting temperature material that defines a first melting temperature greater than a second melting temperature of the molten metal.

Abstract: A method for die casting a component includes inserting at least one sacrificial core into a die cavity of a die comprised of a plurality of die elements. Molten metal is injected into the die cavity. The molten metal is solidified within the die cavity to form the component. The plurality of die elements are disassembled from the component, and the at least one sacrificial core is destructively removed from the component.

Abstract: A method of investment casting includes casting a liquid nickel- or cobalt-based superalloy in an investment casting mold. The superalloy includes an yttrium alloying element that is subject to reactive loss during the casting. Loss of the yttrium is limited by using a zircon-containing facecoat on a refractory investment wall in the investment casting mold. The facecoat contacts the liquid nickel- or cobalt-based superalloy during the casting. Prior to the casting, a zircon-containing slurry is used to form the facecoat. After solidification of the nickel- or cobalt-based superalloy, the refractory investment wall is removed from the solidified superalloy.

Abstract: Shot sleeves for high temperature die casting include a nickel-based alloy having a low modulus single crystal with axi-symmetric orientation.

Abstract: A method of manufacturing a component in a die casting cell that includes a die casting system according to an exemplary aspect of the present disclosure includes, among other things, isolating a first chamber from a second chamber of the die casting system, melting a charge of material in the first chamber, sealing the second chamber relative to the first chamber, and simultaneously injecting the charge of material within the second chamber to cast the component and melting a second charge of material within the first chamber.

Abstract: A method of fabricating an investment casting mold includes using a zircon-containing slurry to form a facecoat of a refractory investment wall of a mold cavity in an investment casting mold. The zircon-containing slurry includes, by weight, at least 70% of zircon powder. Also disclosed is a slurry for use in an investment casting mold. The slurry includes, by weight, at least 70% of zircon powder, 10%-30% of colloidal silica material, and 1%-10% of a carrier solvent. The method and slurry can be used to fabricate an investment casting mold that has a refractory investment wall with a facecoat having, by weight, at least 70% zircon.

Abstract: A system and methods are provided for removing core elements of cast components. In one embodiment, a method includes controlling a first high temperature autoclave cycle for a cast component in a vessel with a first solution concentration to remove at least a first portion of core elements, wherein the first solution concentration, temperature and pressure in the vessel are controlled to expose one or more casting pins in the cast component. The method may also include controlling a second high temperature autoclave cycle for the cast component in the vessel with second solution concentration, wherein the second solution concentration, temperature and pressure in the vessel during the second high temperature autoclave cycle are controlled to loosen one or more of the casting pins from the cast component, and controlling one or more low temperature autoclave cycles to remove core and casting pins from the cast component.

Abstract: A method to manufacture reticulated metal foam includes coating a precursor in a molten wax to increase ligament thickness; and investment coating the molten wax coated precursor with a ceramic plaster.

Abstract: A system and methods are provided for removing core elements of cast components. In one embodiment, a method includes controlling a first high temperature autoclave cycle for a cast component in a vessel with a first solution concentration to remove at least a first portion of core elements, wherein the first solution concentration, temperature and pressure in the vessel are controlled to expose one or more casting pins in the cast component. The method may also include controlling a second high temperature autoclave cycle for the cast component in the vessel with second solution concentration, wherein the second solution concentration, temperature and pressure in the vessel during the second high temperature autoclave cycle are controlled to loosen one or more of the casting pins from the cast component, and controlling one or more low temperature autoclave cycles to remove core and casting pins from the cast component.

Abstract: A method of forming an engine component according to an exemplary aspect of the present disclosure includes, among other things, introducing molten metal into a cavity between a shell and a casting article in the shell. The casting article includes a ceramic portion and a plurality of fibers. The method further includes separately removing the ceramic portion and the fibers from an interior of the component.

Abstract: A method of forming an engine component according to an exemplary aspect of the present disclosure includes, among other things, introducing molten metal into a cavity between a shell and a casting article in the shell. The casting article includes a ceramic portion and a plurality of fibers. The method further includes separately removing the ceramic portion and the fibers from an interior of the component.

Abstract: High modulus turbine shafts and high modulus cylindrical articles are described as are the process parameters for producing these shafts and cylindrical articles. The shafts/articles have a high Young's modulus as a result of having high modulus <111> crystal texture along the longitudinal axis of the shaft/article. The shafts are produced from directionally solidified seeded <111> single crystal cylinders that are axisymmetrically hot worked before a limited recrystallization process is carried out at a temperature below the recrystallization temperature of the alloy. The disclosed process produces an intense singular <111> texture and results in shaft or cylindrical article with a Young's modulus that is at least 40% greater than that of conventional nickel or iron alloys or conventional steels.

Abstract: A method to manufacture reticulated metal foam includes coating a precursor in a molten wax to increase ligament thickness; and investment coating the molten wax coated precursor with a ceramic plaster.

Abstract: An investment casting apparatus includes a furnace having an opening, a mold support, and a multi-axis actuator connected with the mold support and configured to retract the mold support from the opening with multiple-axis motion. An investment casting method includes withdrawing, with multiple-axis motion, a mold through the opening of the furnace to solidify a molten metal- or metalloid-based material in the mold. The apparatus and method can be used to form a cast article that has a body formed of the metal- or metalloid-based material. The body has a multi-textured, single crystal microstructure.

Abstract: High modulus turbine shafts and high modulus cylindrical articles are described as are the process parameters for producing these shafts and cylindrical articles. The shafts/articles have a high Young's modulus as a result of having high modulus <111> crystal texture along the longitudinal axis of the shaft/article. The shafts are produced from directionally solidified seeded <111> single crystal cylinders that are axisymmetrically hot worked before a limited recrystallization process is carried out at a temperature below the recrystallization temperature of the alloy. The disclosed process produces an intense singular <111> texture and results in shaft or cylindrical article with a Young's modulus that is at least 40% greater than that of conventional nickel or iron alloys or conventional steels.

Abstract: A high-temperature die casting die includes a first die plate with a first recess and a second die plate with a second recess, the first and second recesses defining a main part cavity and gating. A grain selector is in fluid communication with the main cavity, and an in situ zone refining apparatus is adapted to apply a localized thermal gradient to at least one of the first and second die plates. The localized thermal gradient and the at least one die plate are movable relative to each other so as to apply the localized thermal gradient along a first direction extending from the grain selector longitudinally across the main part cavity.

Abstract: A method for desulfurizing a metal alloy comprises heating the metal alloy to a molten state. A gaseous desulfurizing compound is bubbled through the molten alloy to form a solid sulfur-containing waste phase and a molten reduced-sulfur alloy phase. The solid waste phase and the molten reduced-sulfur alloy phase are separated. The gaseous desulfurizing compound includes a constituent element selected from the group: alkali metals, alkaline earth metals, and rare earth metals.

Abstract: A method of manufacturing includes providing a casting assembly, providing a material having solid, transition, and liquid phases, heating the material to form the liquid phase, supplying the material to the casting assembly, cooling the material, monitoring the solidification of the material from the liquid phase through the transition phase, and moving one of the casting mold or the reusable core in a first direction relative to the other when a substantial portion of the reusable core contacts the transition phase. The casting assembly comprises a casting mold and a reusable core inserted within the casting mold.

Abstract: A method to manufacture reticulated metal foam includes coating a precursor in a molten wax to increase ligament thickness; and investment coating the molten wax coated precursor with a ceramic plaster.

Abstract: A die casting system includes a die having a plurality of die elements that define a die cavity. A charge of material is received in the die cavity. The charge of material comprises a refractory metal intermetallic composite based material system. A die casting method includes casting a component from the refractory metal intermetallic composite based material system.