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 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 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 casting system includes a core and a shell positioned relative to the core. A barrier coating is applied on at least one of the core and the shell, and may be applied to both the core and the shell. The barrier coating limits reaction between the casting system and a casting alloy.

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 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 method of fabricating a die cast article is disclosed and includes forming an insert with an additive manufacturing process to define a cavity for generating desired part geometry. The insert is then mounted within a mold tool, material is injected into the cavity to fill the cavity and form a cast article.

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 die casting system includes a die, a shot tube, a melting system and a vacuum system. The die includes a plurality of die components that define a die cavity. The shot tube is in fluid communication with the die cavity and is operable to deliver a charge of material to the die cavity. The melting system is positioned adjacent to the die and includes an alloy loader, a melting unit and a crucible. The vacuum system defines a first chamber and a second chamber separated from the first chamber by an isolation valve. The melting system is disposed within the first chamber, and the die is disposed within the second chamber.

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 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 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 refractory metal core for forming internal features in a turbine engine component has a core formed from a refractory metal material; and the core has at least one blended surface on at least one edge of the core.

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: 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 rapid manufacturing method includes forming tooling in a rapid manufacturing process. The tooling is coated with a conductive material.

Abstract: A high-temperature die casting apparatus comprises a die and a chiller. The die has a first die plate and a second die plate with respective first and second recesses defining a main part cavity and gating. The apparatus can be used for die casting metal alloys having a melting temperature of at least about 1500° F. (about 815° C.).

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 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 may comprises a refractory metal intermetallic composite based material system. The charge of material may also comprise a composite material.