Abstract: A method of forming a cast component and a method of forming a casting mold. The method is performed by connecting at least one wax gate component to a ceramic core-shell mold. The ceramic core-shell mold includes at least a first core portion, a first shell portion, and a second shell portion, wherein the first shell portion is adapted to interface with at least the second shell portion to form at least one first cavity between the core portion and the first and second shell portions. The core-shell mold may be inspected and assembled prior to connection of the wax gate component. At least a portion of the ceramic core-shell mold and the wax gate component is coated with a second ceramic material. The wax gate component is then removed to form a second cavity in fluid communication with the first cavity.

Abstract: A method of forming a cast component and a method of forming a casting mold. The method is performed by connecting at least one wax gate component to a ceramic core-shell mold. The ceramic core-shell mold includes at least a filter, first core portion, a first shell portion, and at least one first cavity between the core portion and the first shell portion. The core-shell mold may be manufactured using an additive manufacturing process and may include an integrated ceramic filter. At least a portion of the ceramic core-shell mold and the wax gate component is coated with a second ceramic material. The wax gate component is then removed to form a second cavity in fluid communication with the first cavity.

Abstract: In a method for removing a carbon-containing pattern material from a casting shell, a first step evaporates and pyrolizes the pattern material to leave carbon and a second step oxidizes the carbon.

Abstract: A disposable core die includes a first portion defining an inlet configured to receive a slurry therethrough, a second portion integrally formed downstream from the first portion and configured to receive the slurry from the first portion, and a third portion integrally formed downstream from the second portion. The second portion includes a plurality of hollow tubes that are substantially coaxially aligned and have a wall thickness within a range defined between about 0.1 mm and about 0.5 mm, and the third portion defines an outlet configured to discharge excess slurry from the second portion.

Abstract: A method of forming a component having an internal passage defined therein is provided. The method includes positioning a jacketed core with respect to a mold. The jacketed core includes a hollow structure formed at least partially by an additive manufacturing process, and an inner core disposed within the hollow structure. The method also includes introducing a component material in a molten state into a cavity of the mold, and cooling the component material in the cavity to form the component. The inner core is positioned to define the internal passage within the component.

Abstract: A method is provided for casting an article such as a blade having an attachment root and an airfoil, the airfoil having a proximal end and a distal end. The method includes introducing a molten alloy into a mold. A composition of the introduced alloy is varied during the introduction so as to produce a compositional variation.

Abstract: Certain exemplary embodiments can provide a system, machine, device, manufacture, and/or composition of matter configured for and/or resulting from, and/or a method for, activities that can comprise and/or relate to, investment casting a product in a mold, the product comprising at least one wall, the mold comprising a core, an inner primary shell, and an outer secondary shell.

Abstract: A composition having nanoparticles of a refractory-metal boride and a carbonaceous matrix. The composition is not in the form of a powder. A composition comprising a metal component, boron, and an organic component. The metal component is nanoparticles or particles of a refractory metal or a refractory-metal compound capable of decomposing into refractory metal nanoparticles. The organic component is an organic compound having a char yield of at least 60% by weight or a thermoset made from the organic compound. A method of combining particles of a refractory metal or a refractory-metal compound capable of reacting or decomposing into refractory-metal nanoparticles, boron, and an organic compound having a char yield of at least 60% by weight to form a precursor mixture. A composition having nanoparticles of a refractory-metal boride that is not in the form of a powder.

Abstract: A composite core for forming a passage in an investment casting mold is provided including a core element. A generally hollow structural element is positioned about an exterior of the core element. The structural element is configured to deform when a force is applied to the structural element. A rigid shell element is integrally formed about the structural element. The shell element is configured to break when the structural element deforms.

Abstract: A method for producing cores and molds for the foundry industry utilizing a flowable fire-resistant primary molding material. The method includes an acid applied to the flowable fire resistant primary molding material to obtain an acid-coated fire-resistant primary molding material. A binder that can be cured by acid is applied to the acid-coated fire resistant primary molding material to obtain a fire-resistant primary molding material coated with a binder. The fire-resistant primary molding material coated with a binder is then molded into a molded body, and-the molded body is cured. The acid used is a mixture of methane sulfonic acid and at least one sulfur-free acid. The casting molds can be produced having reduced emission of harmful compounds during casting.

Abstract: A method for machining a sand molding element, comprising: inserting at least one hollow center body having an internal cavity in a predetermined position in a casting flask; filling the internal cavity of the hollow center body with unbonded sand; filling the casting flask with bonded sand to obtain a sand block; machining a mold cavity in the sand block; and emptying the internal cavity from the unbounded sand. There is also provided a method for machining a molding core from a sand block, comprising: providing a core base member having a concave upper surface; forming a sand block on the core base member with a lower surface of the sand block resting on the concave upper surface; and machining the molding core into the sand block, the molding core having a convex lower surface complementary to the concave upper surface of the core base member.

Abstract: A component casting apparatus includes a mold to receive a molten solid for casting a component. The mold includes a first sacrificial layer to define a housing of the component and a second sacrificial layer to form at least one core passage of the component in response to contact from the molten solid. The component casting apparatus further includes a trusset disposed against an outer surface of the second sacrificial layer and formed from metal to support the second sacrificial layer.

Abstract: A method is provided for making a mold for casting advanced turbine airfoils (e.g. gas turbine blade and vane castings) which can include complex internal and external air cooling features to improve efficiency of airfoil cooling during operation in the gas turbine hot gas stream. The method steps involve incorporating at least one fugitive insert in a ceramic material in a manner to form a core and at least a portion of an integral, cooperating mold wall wherein the core defines an internal cooling feature to be imparted to the cast airfoil and the at least portion of the mold wall has an inner surface that defines an external cooling feature to be imparted to the cast airfoil, selectively removing the fugitive insert, and incorporating the core and the at least portion of the integral, cooperating mold wall in a mold for receiving molten metal or alloy cast in the mold.

Abstract: A composite core for forming a passage in an investment casting mold is provided including a generally hollow structural element. The structural element is configured to deform when a force is applied to an end thereof. A rigid shell element is formed about the structural element. The shell element extends beyond both an interior surface and an exterior surface of the structural element. The shell element is configured to shatter when the structural element deforms.

Abstract: The process for investment casting of complex shapes has historically had 6 basic steps in it. Depending upon the path taken, these discrete steps have been reduced to either 5 steps, or to 2 steps, discarding the unwanted steps. Instead of having to generate the shape of each sacrificial pattern, the process generates either (A) a male tree containing a plurality of sacrificial patterns, already on their runners, onto which a mold shell can be formed, or, (B) a female shell, made of a refractory material, and forming internally the outside surfaces of the plurality of patterns and runners. This process removes both capital expenditure for tooling and process time by up to 90%. By removing several lengthy, time-dependant steps from the process the part cost and lead time are reduced.

Abstract: An arrangement and method in a ram-up machine (1) for moulds (2) for metal casting (10) comprising:—a squeeze plate (3) carrying a first mould pattern (32)—a horizontally movable piston (31) for operating the squeeze plate (3) and a finished mould block (2),—a sand supply system (7)—a swing plate (4) carrying a second mould pattern (42), the swing plate (4) is configured to be translatorily movable in a horizontal direction to a released position (4r) and further to be pivotable upwardly to a sidestep position (4s),—a feeder element insertion configuration (50) wherein one or plurality of feeder elements (5) are configured to be attached to the second mould pattern (42) when during operation the swing plate (4) carrying the second mould pattern (42) is pivoted to the sidestep position (4s).

Abstract: A tire vulcanizing mold manufacturing method for manufacturing of a mold including a vent mechanism, and a tire vulcanizing mold manufactured using such method are disclosed. Blades each with anchor portions are mounted on a plaster mold with only the anchor portions embedded in the plaster mold. A portion of each blade mounted on the plaster mold is covered with a cover layer made of a destructible fire-resistant material. Molten metal is poured over a surface of the plaster mold to cast a mold to which the shape of the surface is transferred and in which each blade is buried. The anchor portions protruding from the surface of the mold are removed, and the cover layer is removed to form a slit around the blade. A vent opening forming member is removed to form a vent opening. The slit and the vent opening communicate with each other.

Abstract: A tire vulcanizing mold manufacturing method for manufacturing of a mold including a vent mechanism, and a tire vulcanizing mold manufactured using such method are disclosed. Blades each with anchor portions are mounted on a plaster mold with only the anchor portions embedded in the plaster mold. A portion of each blade mounted on the plaster mold is covered with a cover layer made of a destructible fire-resistant material. Molten metal is poured over a surface of the plaster mold to cast a mold to which the shape of the surface is transferred and in which each blade is buried. The anchor portions protruding from the surface of the mold are removed, and the cover layer is removed to form a slit around the blade. A vent opening forming member is removed to form a vent opening. The slit and the vent opening communicate with each other.

Abstract: A rotor comprising: a two sided braking surface, a base portion; a hat portion connected to the two sided braking surface via the base portion, the hat portion including: a mounting face and a hat wall; and wherein the base portion includes holes and the hat wall includes holes.

Abstract: A mold core package for forming a molding tool includes a plurality of stacked particulate layers having a binding agent. The plurality of stacked particulate layers form sacrificial walls. An elongate sacrificial displacement line extends through the mold core package adjacent a forming surface of the mold core package. A mold cavity is defined by the stacked particulate layers.

Abstract: A method for machining a sand molding element, comprising: inserting at least one hollow center body having an internal cavity in a predetermined position in a casting flask; filling the internal cavity of the hollow center body with unbonded sand; filling the casting flask with bonded sand to obtain a sand block; machining a mold cavity in the sand block; and emptying the internal cavity from the unbounded sand. There is also provided a method for machining a molding core from a sand block, comprising: providing a core base member having a concave upper surface; forming a sand block on the core base member with a lower surface of the sand block resting on the concave upper surface; and machining the molding core into the sand block, the molding core having a convex lower surface complementary to the concave upper surface of the core base member.

Abstract: A system for producing cast components from molten metal. One form of the present invention includes a system for the precision pouring of molten metal within a casting mold. The precision pouring system is driven by a pressure differential.

Abstract: A mold core package for forming a molding tool includes a plurality of stacked particulate layers having a binding agent. The plurality of stacked particulate layers form sacrificial walls. An elongate sacrificial displacement line extends through the mold core package adjacent a forming surface of the mold core package. A mold cavity is defined by the stacked particulate layers.

Abstract: A casting assembly for manufacturing a lock of a railcar coupler includes drag and cope portions of a first mold that defines exterior surfaces of the lock, wherein the first mold comprises a first molding material. The casting assembly also includes a second mold formed of a second molding material. The second mold defines a cavity with an interior surface that substantially complements an exterior surface of the first mold. A down sprue is formed in the second mold. A gating system is formed in the second mold that and is in fluid communication with the down sprue. An in-gate is formed in the second mold and is in fluid communication with the gating system and the first mold.

Abstract: A method for manufacturing a railcar coupler knuckle includes, before casting, positioning an external chill within a cope mold portion and a drag mold portion offset from and adjacent internal walls of a pulling face and a throat of the cope and drag mold portions, thus producing a casting with reduced micro-shrinkage in at least the throat, a high-stress section of the casting. Use of subsurface chills produces an improved surface with fewer inclusions when compared to an equivalent surface produced in a process without use of a subsurface chill. The external chill may be a cone chill of a larger size to improve cooling and solidification at and below the surface. The external chill may also be a cylindrical and/or oblong chill with a tapered design that may correspond to the internal walls of the cope and drag mold portions between the pulling face and the throat.

Abstract: A main body core box assembly for creating coupler head cores which are attachable to various shank cores includes a main body core box including two halves, each half including a pattern configured to form the outer walls of a first head core having a first shank core. A plug is insertable into an end of respective patterns to form a second, alternative head core having a first half of a connection joint attachable to a second shank core that includes a second half of the connection joint, the second shank core being different than the first shank core. The first half of the connection joint may be a male connector, where the plug includes a recess having an angled surface to create a notch on the male connector. The second half of the connection joint may be a female connector with a raised surface corresponding to the notch.

Abstract: A method of manufacturing a casting article for use in a casting process includes rapidly forming the casting article out of a metallic material. A ceramic coating is applied to an exterior surface of the casting article.

Abstract: In the casting of a single crystal component, such as a turbine blade, by the lost wax casting technique, one or more ceramic pieces are positioned on a wax pattern at locations corresponding to parts of the cast component where relatively quick solidification of molten metal may occur during casting. A coating is subsequently formed around the wax pattern to define a mould, whereupon the wax is removed to leave the one or more ceramic pieces within the formed mould.

Abstract: This invention provides methods for forming stainless steel, single-piece, multi-chambered water faucets and fixtures with a single one-body construction. A variety of stainless steel products can be formed with a main body having an internal hollow region and a plurality of dividing chambers. The main body may be constructed using high temperature resistant ceramic cores in combination with a lost wax investment casting process. The stainless steel products formed from a single piece construction can eliminate the need for additional time-consuming manufacturing steps, such as parts welding, screw assembly, or precision press fitting. In addition, water faucets and fixtures can be provided that are substantially lead-free, non-verdigris, and non-toxic in compliance with environmental regulations and lead/toxic limits.

Abstract: A method of creating an article from investment casting includes forming a ceramic seed well, heating the ceramic seed well to form a hardened ceramic seed well, attaching a meltable pattern to the hardened ceramic seed well, coating the hardened ceramic seed well and the meltable pattern with hardenable ceramic material, heating the hardenable ceramic material to melt the meltable pattern, removing the meltable pattern from the hardenable ceramic material, firing the hardenable ceramic material to form a ceramic mold having a cavity, placing a seed within the hardened ceramic seed well, and pouring molten metal into the hardened ceramic seed well and the cavity. The cavity of the ceramic mold is in communication with the hardened ceramic seed well.

Abstract: A tire vulcanization mold manufacturing method and a tire vulcanization mold by which an exhaust mechanism capable of ensuring sufficient exhaust can be formed in fewer processing steps are provided. When a mold having a surface 11a of a gypsum mold 11 transferred thereto is to be manufactured by pouring molten metal M onto the surface 11a of the gypsum mold 11 and solidifying the molten metal M, a tubular body 7 having a slit 8 allowing hollow inside 7a to communicate with the outside is disposed in such a way that the slit 8 is brought into contact with the surface 11a of the gypsum mold 11. Thereafter, the molten metal M is poured onto the surface 11a of the gypsum mold 11 in such a way that the tubular body 7 is buried in the mold while the slit 8 is exposed on a tire molding surface of the mold.

Abstract: A core-in-a-core casting method and hybrid core (40) for use in the method. An inner core (42) formed of process-inert particles disposed in a binder material is used as a mold for casting an outer core ((44) formed of particles that will sinter during a subsequent firing step. The inner core provides mechanical support for the outer core during the firing step, and during which the inner core devolves into compacted but unbonded particles that can be removed conveniently from the outer core following the firing step to reveal the fired hollow outer core (44).

Abstract: Described is a procedure for layered composition of models, whereby at least a first material is applied to an assembly platform, followed by selective application of a second material layer; these two application steps are repeated until the required model is achieved and both materials form a solid structure in an appropriate mixture ratio. The first material comprises a molding sand; the first and/or second material comprises a bonding agent encompassing a salt-crystal binder and/or protein binder.

Abstract: A method involves forming a core assembly. The forming includes deforming a wire, the deforming including increasing a transverse linear dimension along at least one portion of the wire.

Abstract: A method for manufacturing an investment casting core uses a metallic blank having a thickness between parallel first and second faces less than a width and length transverse thereto. The blank is locally thinned from at least one of the first and second faces. The local thinning forms a taper on a leading portion of the RMC. The blank is through-cut across the thickness. The blank is inserted into the leading portion into a slot in a pre-formed ceramic core.

Abstract: A method for the layered construction of models is disclosed, whereby at least one first material is applied to a building platform and then a second material is selectively applied in layers. Both application steps are then repeated until the desired model is obtained and the both materials form a solid body with a desired mixing ratio. The first material comprises a moulding sand and the first and/or the second material comprises a binder, comprising a crystalline salt binder, or/and a protein binder.

Abstract: The invention relates to a method for producing cores and molds for the foundry industry, wherein—a flowable fire-resistant primary molding material is provided. An acid is applied to the flowable fire resistant primary molding material, thus obtaining an acid-coated fire-resistant primary molding material. A binder that can be cured by acid is applied to the acid-coated fire resistant primary molding material, thus obtaining a fire-resistant primary molding material coated with a binder. The fire-resistant primary molding material coated with a binder is molded into a molded body, and-the molded body is cured, wherein the acid is a mixture of methane sulfonic acid and at least one further sulfur-free acid. The invention further relates to a mold material mixture as it is used in said method. With the method or the mold material mixture, casting molds can be produced having reduced emission of harmful compounds during casting.

Abstract: A process for producing a mold includes introducing a composition including a particulate, refractory material and a binder into a hollow model having an interior cavity which determines contours of all surfaces of the mold or a mold part, wherein the model includes at least two separate parts to permit removal of the mold, and applying a second composition containing at least one organosilicon component and at least one solvent to at least one of the separable parts before use.

Abstract: The invention relates to a chassis component for an automobile and a method for producing such chassis component. A mineral core body made of silicate is cast inside a light metal casting, and the blank produced in this manner is processed by forging, forming they chassis component 1. The density and strength of the base body of the light metal casting forming the chassis component as well as of the core body can be adjusted during the forging process.

Abstract: A method for producing a casting mold from a composite mold material for foundry purposes that is composed of different kinds of mold materials that are heat-resistant for the casting of metals and that differ in substantive composition or have different contents of organic or inorganic binders. A solid mold body is prepared from a foundry mold material A that is completely or partially encased during its preparation with a free-flowing chemically bonded foundry mold material B. A composite mold material block is formed after the hardening of the foundry mold material B, which is then machined by a cutting method such as milling, boring, turning, or grinding. The mold cavity is introduced into the mold body consisting of the foundry mold material A, and the inflow system and the feed system are introduced into the mold material block consisting of the foundry mold material B, using CAD data.

Abstract: In the casting of a single crystal component, such as a turbine blade, by the lost wax casting technique, one or more ceramic pieces are positioned on a wax pattern at locations corresponding to parts of the cast component where relatively quick solidification of molten metal may occur during casting. A coating is subsequently formed around the wax pattern to define a mould, whereupon the wax is removed to leave the one or more ceramic pieces within the formed mould.

Abstract: A method involves forming a core assembly. The forming includes molding a first ceramic core over a first refractory metal core to form a core subassembly. The subassembly is assembled to a second ceramic core.

Abstract: Methods involving providing an integrated disposable core and shell die of an authentic gas turbine component, inserting at least one through-rod through the integrated disposable core and shell die, casting an integrated core and shell mold inside of the integrated disposable core and shell die, removing the integrated disposable core and shell die to obtain the integrated core and shell casting mold having the at least one through-rod disposed therein, casting an authentic gas turbine component replica using the integrated core and shell casting mold, and removing the integrated core and shell casting mold and the at least one through-rod to obtain the authentic gas turbine component replica.

Abstract: A volatile liquid loadable porous metal or ceramic container and manufacturing method thereof provided with a structural body formed by metal or ceramic sintering and provided with breathable pores, which extend from an outer surface of the structural body to the interior of the structural body, and the breathable pores form spaces to transport or/and store liquid. The manufacturing method includes: a. taking a low temperature volatile material as the core; b. completely covering the aforementioned core with metal or ceramic powder in the predetermined mold; c. controlling compactness of the metal or ceramic powder; d. sintering of the core at a temperature higher than the vaporization temperature to cause gaseous effusion of the core; e. taking off the predetermined mold after completing sintering.

Abstract: In-Place Cope Molding or “IPCM,” is designed to reduce or eliminate certain inefficiencies present in traditional molding techniques during production of the cope half of a sand mold. IPCM allows the cope half of the mold to be produced on top of the drag half of the mold by use of a separation barrier which supports the sand above the mold cavity in the drag. This method reduces or eliminates parting line flash, and also avoids the need to turn over or otherwise handle the cope, allowing the cope to be made thinner than a traditional cope and allowing for lower material costs.

Abstract: The invention relates to a method for the production of a pattern for precision casting representation of turbine component comprising at least one cavity, whereby the prepared pattern comprises at least one core and an outer contour pattern, at least partly enclosing the core and at least partly defining the outer contour of the turbine component. The core is made from a hardening core material, which hardens during the course of the method and the outer contour pattern is made from a combustible or fusible material. The outer contour model is first produced with at least one cavity corresponding to the at least one cavity of the turbine component and subsequently, in order to form the at least one care, the hardening core material is introduced into the at least one cavity and hardened.

Abstract: A sprue former of the type used to produce a casting mold includes a generally hollow body or a body having hollow sections. The body includes an inlet forming member and at least one first interface member. The inlet forming member is configured to provide an inlet cavity in the casting mold to enable casting material to enter the casting mold. The first interface members are configured to couple to casting patterns. The casting patterns represent items to be cast. The body can also includes a reservoir forming member and at least one connecting member coupling the reservoir forming member to the inlet forming member.

Abstract: A lightweight part and process and device of making the same, the lightweight part including an inner core including a metal foam. A dense core surface layer is metallically joined to the inner core. An outer wall includes an essentially pore-free cast metal layer that is at least one of positively engaged with the dense core surface layer and surrounding the inner core, and metallically joined to the dense core surface layer and surrounding the inner core. The process includes creating a core part by forming the dense core surface layer, forming the inner core of a metal foam, and metallically joining together the inner core and the dense core surface layer. The process further includes creating a finished part by positioning the core part in a casting mold, feeding a melt material into the casting mold, and allowing the melt material to solidify so as to form the outer wall.

Abstract: A sand casting facing composition comprises a dry mixture of about 77% fine sand, 5% binder, 6% green system sand and 12% burned system sand. The fine sand is mulled with 5.8% wt/wt oil per total dry mixture and catalyst at about 0.5% wt/wt. Preferably, fine sand and binder are mulled with oil, catalyst, green system sand and screened burned system. The mulled mixture is rested, mulled again and rested again before use as facing sand for achieving accurate reproduction of the pattern's fine detail. A method of preparing the mold and preserving fine detail comprises riddling the pattern with a thin layer of the facing sand composition, compacting, riddling with dry system sand and riddling with system sand before compacting about the periphery of the pattern. Final layers of system sand are applied and compacted over the entire pattern.

Abstract: A new mold solves problems that arise from differential changes in geometry inherent to casting metal in a ceramic mold, by control of the internal morphology between the surfaces of the mold that face the casting, and that face the external environment. Layered fabrication techniques are used to create a ceramic mold. For example, an internal geometry composed of a cellular arrangement of voids may be created within the mold wall. Structures may be designed and fabricated so that the ceramic mold fails at an appropriate time during the solidification and/or cooling of the casting. Thus, the casting itself is not damaged. The mold fails to avoid rupture, or even distortion, of the casting. A thin shell of ceramic defines the casting cavity. This shell must be thin enough to fail due to the stresses induced (primarily compressive) by the metal next to it and partly adherent to it.