Abstract: A gravity pour vacuum casting method and apparatus providing uniform set-up provisions for gas permeable molds regardless of mold size, shape, or mold type employed in accordance with the present invention. Apparatus includes a sprue-forming device that when combined with a disposable foundry patter and subsequently invested together as a unit forms a gas permeable mold in accordance with the present invention, and further includes a vacuum chamber configured to match corresponding counterparts of said sprue-forming device.

Abstract: Refractory coated gelatin-bonded foundry sand core made by waterproofing the surface of the core and immersing the waterproofed core in an aqueous refractory suspension to deposit the refractory.

Abstract: A process for making a casting mold or core utilizes a refractory composition including a slurry of yttria, an acid and an organic solvent. The composition is applied to a mold or pattern, dried, and fired to produce a mold or a layer of a mold or core. The articles produced are relatively unreactive with titanium and titanium alloys during casting.

Abstract: A method for producing semi-permanent casting tooling, including the steps of blending a high char resin with a refractory powder to form a plastic moldable material; shaping the plastic moldable material to form a green tooling body; and heating the green tooling body to convert the high char resin into carbon char to form reusable casting tooling. The casting tooling can be used in casting processes including die casting, permanent mold casting and pressure infiltration casting.

Abstract: This invention provides a process for preparing a refractory molded article comprising the steps of (a) forming a molded article matrix from an aggregate and the first binder, (b) impregnating the molded article matrix formed in step (a) with the second binder consisting of an alcoholic solution of one kind or two or more kinds of metal alkoxides selected from alkoxides of metals of Group 4A or Group 4B (excepting carbon) and Group 3A or Group 3B of the periodic table and their partial hydrolysates and an alkaline compound of alkali metal or alkaline earth metal (one kind or a mixture of two or more kinds selected from alkoxides, hydroxides and salts of the metal) and (c) drying and firing the molded article matrix at high temperature and also provides a binder for the preparation of such refractory molded article.

Abstract: Articles such as molds for thermoplastics, having an insulating layer preferably of resin deposited on the metal core materials, have a second layer of metal suspended in resin deposited on said insulating layer. The second layer may contain metal in platelet form as the inner mold surface, or may contain metal in fiber, whisker or irregular form with a further metal coating deposited thereon to provide resistance to abrasion. In the latter case, the adhesion of the further metal coating to the mold surface is higher than is the case if no metal-containing resin layer is present.

Abstract: The invention concerns a new material for molding elements as well as the molds produced in this manner. This material contains more than 30% vitreous fused silica and various adjuvants and binders and presents the advantage of the possibility of modulating the thermal conductivity of the molds. Application to all types of industries utilizing shaping by molding of liquid or paste-like materials, or by the hot deformation of flat products.

Abstract: Molds for injection molding are produced by providing a primary mold core, coating the primary mold core with a water-resistant coating layer, applying on the water-resistant coating layer a separating layer, spraying a metal shell on the separating layer, arranging a rear filling on the shell so as to form a tool part, and supplying water to the water-soluble layer so as to remove the tool part.

Abstract: A core assembly is formed by molding a destructible plastic form in abutting relation to a rigid bonded core. The core assembly can be used for casting large or long and thin castings. The rigid bonded core reinforces the plastic form against flexural and torsional forces as well as forces within the plastic tending to change the dimensional configuration of the plastic form.

Abstract: Both a pattern member and a body of expansion material are covered with a layer of ceramic mold material. The body of expansion material has a coefficient of thermal expansion which is greater than the coefficient of thermal expansion of the ceramic mold material. The layer of ceramic mold material and the body of expansion material are heated. This results in a cracking of the layer of ceramic mold material by the body of expansion material due to greater thermal expansion of the body of expansion material as it is heated. During the step of heating the ceramic mold material and body of expansion material, the pattern member is melted to separate the pattern from the layer of ceramic mold material.

Abstract: A static casting mold for hollow cast product with bottom comprising a top lid, a core and an outer mold section, the core being attached to the top lid and disposed inside the outer mold section. The outer mold section includes a lateral mold section and a lower mold section. The lateral mold section is formed at its inner peripheral wall portion with a composite cooling section by stacking chiller blocks and interposing therebetween refractory sands and at its outer wall portion with refractory sands. Cooling pipes includes a first and second pipes. A first pipe extends longitudinally through the refractory sands at the outer wall portion and a second pipe extends longitudinally through the inner wall portion in contact with at least a part of each of the chiller blocks, the first and second pipes being connected at their lower portions through the bend portion. The chiller blocks are cooled by water flowing in the second pipes.

Abstract: A method is disclosed for increasing productivity when casting Vee configuration engine blocks in a given size, two-part refractory mold having a single parting plane.

Abstract: Process for obtaining, by pig iron casting, machine elements provided with protection cages suitable to preserve delicate portions of machine elements from breaking and deforming during the production phase. The process consists in applying raised impressions of the cages on a pattern for green casting which impression corresponds to a print of a hardened shell reproducing the outer portions of the machine elements.

Abstract: Method for investment casting of metal matrix composites by vacuum infiltration using a ceramic mold formed directly on the pattern.

Abstract: An improved method is utilized to make a mold for a cast product having a plurality of spaced apart surfaces. Although the method could be used for forming molds for different products, the method is advantageously used to form a mold for a cast product having a plurality of airfoils disposed in a circular array. To form the mold, a plurality of airfoil pattern segments are placed in a circular array with surfaces of the segments abutting at joints which are free of material interconnecting the segments. A coating of liquid ceramic mold material is applied over the airfoil pattern segments. Since the joints between the airfoil pattern segments are free of interconnecting material, the liquid ceramic mold material can flow into the joints. After the ceramic mold material has been dried and the airfoil pattern segments disposed of, the ceramic mold material which entered the joints between the airfoil pattern segments forms a plurality of relatively thin projections from the main wall of the mold.

Abstract: A method of forming a mold for use in casting is disclosed. The method includes as a first step forming a positive pattern having a surface the shape of a part to be cast. Next a negative partial pattern is formed having a casting surface complimentary to a selected portion of the surface of the positive pattern and also having a reference surface in a fixed spatial relationship with the casting surface. The casting surface of the negative partial pattern is placed in complimentary engagement with the selected portion of the surface of the positive pattern to form a pattern assembly. A first mold section having a surface complimentary to the reference surface and to the surface of the part is formed by dipping the assembly formed in the preceding step in a ceramic material.

Abstract: An improved method of assembling molds enables the size of successive molds to be adjusted to provide cast articles having a desired size. In practicing the method, a first or initial mold is assembled in a fixture. This initial mold is used to form a cast article. The cast article formed in the initial mold is measured to determine the extent to which the dimensions of the article deviate from predetermined design dimensions. The fixture is then adjusted to compensate for the deviations in the dimensions of the cast article from the intended or design dimensions. A second mold is then assembled in the fixture. Since the fixture has been adjusted to compensate for the inaccuracies in the first mold, a product cast with the second mold will have dimensions closer to the desired dimensions.

Abstract: A method for manufacturing a thermally highly stressed, cooled component, more particularly, a blade for turbine engines. A component of the above-mentioned type has a central supporting core formed of a solid material and has connected thereto several short, radially outwardly projecting ridges which, in turn, carry an outer shroud concentrically encompassing the supporting core, and which is made of a through-porous material, whereby the supporting core, ribs, and outer shroud are cast in a single piece.

Abstract: Disclosed is an improved method for making molds and mold components for use in casting single crystal articles. According to the improved method, a preformed and reusable replica of a mold growth cavity and crystal selector passage is provided, the replica including a cylinder in the form of the desired growth cavity and a helical strand in the form of the desired crystal selector passage, one end of the strand being attached to an end of the cylinder such that their axes are coincident. In one embodiment, the replica is coated with a thin layer of wax or other removable material and then utilized in a variety of mold making processes, including investment molding, to form a growth zone and helical crystal selector in the mold.

Abstract: A segmented mold assembly is utilized to cast a turbine engine component having an annular inner wall and an annular outer wall which are interconnected by a plurality of struts or vanes. The mold assembly includes a plurality of sections which are formed of a ceramic mold material and are interconnected at flange joints. A pair of mold sections are advantageously formed simultaneously by repetitively dipping a single pattern in a slurry of liquid ceramic mold material to form a wet coating on the pattern. This wet coating of ceramic mold material is then dried. After a covering of the desired thickness has been built up by repetitively dipping and drying the coatings on the wax pattern, the wax pattern is destroyed. To facilitate separating the mold sections after destroying the wax pattern, at least some of the wet coatings are wiped away in an area between portions of the wet coatings which will eventually form the mold sections.

Abstract: A mold for casting molten reactive and refractory metals has a facing portion comprising finely divided particles of the fluorides and oxyfluorides of the metals of Groups, Ia, IIa, and IIIa, including the lanthanide and actinide series, of the Periodic Chart (after Mendeleeff) and a back-up portion comprising finely divided particles of shell mold back-up material. The fluoride and oxyfluoride content of the facing portion is essentially inert to titanium and other reactive and refractory molten metals and hence minimizes contamination by mold degradation products of metal objects cast in the mold. SPThis is a continuation-in-part of application Ser. No. 448, 254, filed Mar. 5, 1974, now abandoned; the same being a continuation of application Ser. No. 332,608, filed Feb. 15, 1973, now abandoned; which in turn is a continuation of application Ser. No. 174,662 filed Aug. 25, 1971, now abandoned.

Abstract: An improved method of making a ceramic mold having a cavity in which a cast product is accurately formed includes reinforcing relatively flexible wax pattern material having a configuration which corresponds to the configuration of the mold cavity. Supporting the flexible pattern material with a relatively rigid reinforcing member prevents the pattern material from deflecting during removal from the injection die, pattern storage, pattern and gating assembly and dipping of the pattern in liquid ceramic mold material. Between dipping steps, portions of a wet ceramic coating are wiped away in areas between portions of the wet coating which will eventually form mold sections. After the ceramic mold material on the pattern has been dried, the pattern material is destroyed by heating or other methods. The resulting mold sections are then separated and the rigid reinforcing member removed from between the mold sections.

Abstract: An improved method of forming a shell mold for casting having a shrink bob is provided. A tubular frusto-conical shrink bob, or riser, is first formed from sand and a plastic or resin binder such that both the apex and base of the riser are open. The riser is then inverted and positioned on a casting pattern with the apex of the riser abutting against the casting pattern. The entire pattern is then cast with a thermosetting material, such as sand and a binder, such that the thermosetting material bonds to both the pattern and the riser. After hardening, the thermosetting material with the attached riser forms a shell mold which is subsequently utilized in a foundry casting operation.

Abstract: A method of producing a reduced-pressure-shaped mould in which at least in the region of a sprue runner of the mould to be formed and in regions where a shield material for the mould material is likely to be destroyed during introduction of the molten material to be moulded, the mould material partially or entirely comprises moulding sand mixed with substantially 0.5% to substantially 3.0% by weight of binder.

Abstract: Self setting molds for metal casting are produced using a liquid alkali metal silicate as the binder and a product obtained by reaction of three moles of glycerin and one mole of glacial acetic acid as the catalyst for the binder.

Abstract: The method envisages calcining ceramic casting moulds, their cooling to between 30.degree. and 60.degree.C, applying particulate material preheated to a temperature between 600.degree. and 850.degree.C to the outside of the moulds followed by the compacting of the material and keeping the moulds in said preheated particulate material for a period lasting between 10 and 40 minutes.

Abstract: A method of manufacturing a cast ferrous metal die wherein an initial die of non-ferrous metal is cast in a mould against a basic metal pattern having a melting point substantially not less than that of the non-ferrous casting metal, the basic metal pattern being preheated and coated with refractory material and the non-ferrous casting metal is cast against the preheated and coated basic pattern in a supercooled condition to minimise thermal shock and heat transference between the casting metal and basic pattern, and forming a further corresponding pattern of refractory material in the initial die, and then using the pattern of refractory material in a mould for casting a cast ferrous metal die from said refractory pattern, the cast ferrous metal die so obtained being of corresponding accuracy to the basic metal pattern.