Abstract: An article includes a first portion having a first grain pattern and a second portion having a second grain pattern different from the first grain pattern. The article is a cast article such as a turbine engine blade.

Abstract: An airfoil includes leading and trailing edges; first and second sides extending from the leading edge to the trailing edge, each side having an exterior surface; a core passage located between the first and second sides and the leading and trailing edges; and a wall structure located between the core passage and the exterior surface of the first side. The wall structure includes a plurality of cooling fluid inlets communicating with the core passage for receiving cooling fluid from the core passage, a plurality of cooling fluid outlets on the exterior surface of the first side for expelling cooling fluid and forming a cooling film along the exterior surface of the first side, and a plurality of cooling passages communicating with the plurality of cooling fluid inlets and the plurality of cooling fluid outlets. At least a portion of one cooling passage extends between adjacent cooling fluid outlets.

Abstract: A hybrid sacrificial core for forming an impingement space and an internal cooling passageway network separate from the impingement space of a part may comprise a ceramic core having a first surface portion for forming the impingement space, and a refractory metal core that forms a plurality of passages of the internal cooling passageway network.

Abstract: A non-electroslag remelting type clean metal ingot mold includes an ingot mold body and a insulating riser arranged on the ingot mold body; an insulated heating and heat preservation device is vertically arranged in the ingot mold body and divides the space in the ingot mold body into a plurality of independent cavity units; and the cavity units are distributed in two rows in the ingot mold body. Because the insulated heating and heat preservation device is arranged in the ingot mold body and divides the space in the ingot mold body into a plurality of independent cavity units, most of impurities and segregates in liquid metals are enriched in the part in contact with the isolation and heat insulation mechanism during the directional solidification and crystallization of the liquid metals and the enriched alloy segregates, and the impurities can be easily eliminated by utilizing flame or other processing methods.

Abstract: A lightweight metal mold having a necessary rigidity is realized. Firstly, an original pattern of an evaporative pattern is formed by machining an evaporative material block. The original pattern includes a three-dimensional mesh structure including a plurality of bar-shaped parts and connecting points that connect ends of the bar-shaped parts and are distributed in a three-dimensional space, and a plurality of block parts having fixed relative positional relationship by being fixed to the three-dimensional mesh structure. Then, at least a portion of at least one or more of the bar-shaped parts composing the original pattern is removed, and replaced with a tube member. Then, a full-mold casting is performed by using the evaporative pattern having the replaced tube member. Positional relationship of the block parts in which surfaces, etc. necessary for the metal mold are formed is fixed by the three-dimensional mesh structure, and the necessary rigidity is secured.

Abstract: A system for forming a soft magnetic bulk material of a predetermined shape from a magnetic material and a source of insulating material. The systems has a heating device; a deposition device; a support configured to support the soft magnetic bulk material of the predetermined shape; and a mask configured as a negative of at least a portion of the predetermined shape. The heating device heats the magnetic material to form particles having a softened state and wherein the deposition device deposits successive layers of particles of the magnetic material in the softened state on the support with the mask located between the deposition device and the support. The mask is indexed to a position relative to the support upon deposition of the successive layers. The mask selectively blocks the successive layers of particles of the magnetic material in the softened state from being deposited on the support forming the soft magnetic bulk material of a predetermined shape on the support.

Abstract: An apparatus for producing a piston for an internal combustion engine by casting, the piston having a cooling channel therein, the apparatus including a fixed die with an upwardly opened cavity in which a core serving to form the cooling channel is to be disposed, a moveable die moveably disposed relative to the fixed die in a vertical direction and including a predetermined engaging portion, a guide die including an engaging portion engageable with the fixed die and having a same shape as that of the engaging portion of the moveable die, and a core retaining mechanism disposed in the guide die to retain the core in a predetermined position.

Abstract: Some embodiments provide methods and systems for casting articles. One example of a method includes providing and positioning a thermal blanket within a mold cavity and then introducing a molten material into the mold cavity and into contact with the thermal blanket. The method allows the molten material to remain in a molten state during a dwell time that extends from the introduction of the molten material at least until the mold cavity is filled. In another example, a method of using a thermal blanket includes keeping a molten material in a molten state during a dwell time extending from first introduction of the molten material until pressurization. Systems including a variety of mold types, one or more thermal blankets, and in some cases preforms and/or inserts are also provided. Also described is a novel thermal blanket and method of manufacturing the same.

Abstract: A method produces a casting, in particular a housing of a turbocharger. Wherein at least one mold part for forming the casting has a respective parting plane which is arranged at a predetermined angle with respect to the longitudinal axis of the casting, and wherein at least one core element is provided.

Abstract: An annular clean metal casting mold has a mold body which includes a cold bottom mold plate and a peripheral cold mold plate in connection with the cold bottom mold plate. An annular hot preservation layer is disposed inside the peripheral cold mold plate. A cyclic clean crystalline region is formed between the peripheral cold mold plate and the annular hot preservation layer. A sacrificial crystalline region is formed inside the cyclic hot preservation layer. As the outer race of the annular clean crystallization zone contacts large area of the peripheral low cold mold plate, releasing heat rapidly, while the inner race contacts the annular hot preservation layer 3, heat dissipation is extremely slow, naturally result in forming orientational crystallization.

Abstract: A cutting insert (20) comprising a cutting portion and a cooling portion. The cutting portion has a rake surface (26), a relief surface (28) and a cutting edge (24) defined at the intersection between the rake surface (26) and the relief surface (28). The cooling portion has an operative surface and a cooling nozzle (32) integrally formed therewith. The nozzle (32) is spaced from the cutting edge (24) and having a cooling aperture (CA2) directed at the cutting edge (24) at an acute angle with respect to the rake surface face (26). The operative surface is one of the rake surface (26) and a surface of the cutting element other than the rake surface (26), disposed at a location more remote from the cutting edge (24) than the rake surface (26), so that the rake surface (26) is disposed between the cutting edge (24) and the cooling aperture (CA2).

Abstract: A mould for one piece casting of a tool, which has a working component of steel and a body of grey iron has a first mould cavity section for the steel and a second mould cavity section for the grey iron, with an interconnection zone therebetween. A dividing plane between the sections is planar and horizontal and located at the interconnection zone. A duct leads from the first section to an accommodation space for possible surplus of steel. In a method for one piece casting of a tool, which has a working component of steel and a body of grey iron with an interconnection zone therebetween, the steel is cast in a first mould cavity section and the grey iron in a second mould cavity section. A dividing plane between the mould cavity sections is planar and horizontal. An accommodation space for surplus of steel is provided to permit steel to flow from the first mould cavity section at the level of the dividing plane into the accommodation space.

Abstract: A clean metal ingot mold comprises an ingot mold body and an insulating riser arranged on the ingot mold body. The bottom mold plate of the ingot mold is provided with at least a ridge connected thereto. The region having a V-shape containing impurities produced during the crystallization process of the liquid metal moves upwards because of the ridge, and then the impurities depart from the centre of the cast ingot and the impurities are more centralized. A water-cooling device is arranged in the ridge to allow the temperature of the metal in the ingot mold to decrease rapidly, and the crystallization process of the metal to be rapid.

Abstract: A process and tools for forming and/or releasing metal preforms, metal shapes and solder balls is described incorporating flexible molds or sheets, injection molded metal such as solder and in the case of solder balls, a liquid or gaseous environment to reduce or remove metal oxides prior to or during metal (solder) reflow to increase surface tension to form spherical or substantially spherical solder-balls.

Abstract: A mold for casting in one piece of a tool with a working component of steel and a body of grey iron with an interconnection zone there between has a first model section corresponding to the working component and a second model section corresponding to the body. The model sections are in contact with one another along a contact plane which is horizontal and planar and which represents the interconnection zone. In a method for producing a mold for one piece casting of a tool with a working component of steel and a body of grey iron with an interconnection zone therebetween; a first model section is produced corresponding to the steel and a second model section corresponding to the grey iron. The model sections are brought into contact with one another with the contact surface horizontally aligned and with the first model section lowermost.

Abstract: The present invention relates to a metal mold for manufacturing a straight wax body for a valve and to the straight metal body thus obtained, said metal mold succeeding in eliminating the traditional concave shape of the ball-type valve body, inside which, and during fluid flow distribution, the flow from the fluid inlet cavity to the fluid distribution cavity causes a flow loss in the direction of the fluid flow outlet via the fluid outlet cavity, thus creating a steep drop in pressure, meaning that by eliminating the concave part of the ball-type valve body and making the fluid inlet, distribution and outlet cavities straight and much wider, a straight valve body is obtained, thus preventing the steep drop in pressure and flow loss.

Abstract: A core die for creating an airfoil includes a first section, a second section mating with the first section, and an insert for creating a slot. The first section and the second section define a body having an outer dimension. The insert is disposed at an angle to the outer dimension. A trip strip includes a first portion disposed in the second section. The first portion is in register with the insert and a thickness is maintained between the first portion and the insert along a length of the insert. The first portion tapers towards the outer dimension and the thickness is filled by the ceramic material between the slot and the first portion.

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 casting apparatus for casting a railcar coupler, which includes a shank portion and a head portion, includes cope and drag portions that define an external shape of the coupler. The casting apparatus also includes one or more cores that define an interior of the shank portion and a separate head core with an exterior that defines an interior of the head portion that includes lock chamber, guard arm side portion, and knuckle side portions of the head. The head core is a single piece with a hollow center section that defines a front face gating system that includes at least one in-gate configured to direct molten material to top and bottom regions of the head to define the lock chamber, guard arm side portion, and knuckle side of the head.

Abstract: Certain exemplary embodiments can provide a system, machine, device, manufacture, circuit, and/or composition of matter adapted for and/or resulting from, and/or a method for activities that can comprise and/or relate to, a first form comprising: a plurality of surface artifacts that substantially spatially replicate a surface geometry of a stacked foil mold; and a prong that is adapted to form a hole in a cast product.

Abstract: A method for producing a brake disc comprising a coupling part having a centered through-hole a friction part on the periphery of the coupling part, and a wall part connecting the coupling part and the friction part, including: producing a mold in which the coupling part, the wall part, and the friction part are integrally formed, wherein a gap prevents molten metal from overflowing between the wall part and the coupling part, interface is formed on the periphery of the coupling part, an overflow is provided outside the wall part opposite the gap; a first injection process of injecting a first material to form the friction part; and a second injection process of injecting a second material to form the coupling part, a mold for producing the brake disc, and the brake disc.

Abstract: This manufacturing apparatus for a multi-channel tube having a plurality of parallel channels includes: a crucible; and a die set for forming the multi-channel tube from molten copper supplied from the crucible, the die set including: a hollow portion having an inner surface shaped like the profile of the multi-channel tube; punches which are inserted into the hollow portion from an inlet end of the hollow portion to define a space between the inner surface of the hollow portion and each of the punches; and a feed passage which is disposed between the crucible and the space, and configured to feed the molten copper from the crucible to the space, the molten copper being supplied from the crucible to the space within the die set through the feed passage to solidify as it passes through the hollow portion.

Abstract: A metal casting apparatus includes a feeder for providing a molten metallic material. A mold includes a sprue and a component cavity. The sprue is arranged to receive the molten metallic material from the feeder and the component cavity is arranged to receive the molten metallic material from the sprue. A starter is arranged adjacent the component cavity and is operable to induce a first grain orientation upon solidification of the molten metallic material. The sprue includes an aborter that is arranged to induce a second grain orientation upon solidification of the molten metallic material.

Abstract: The present disclosure includes a system and article of manufacture comprising a universal sliding door frame. The frame may comprise a first track having a first interface and a second track having a second interface. The second interface may slidably couple to the first interface. In addition, the second interface may be orthogonally inseparable from the first interface. In an embodiment, the frame may comprise a spacer that separates the first track from the second track and slidably couples to the first track via the first interface and the second track via second interface. The spacer may, in addition, be orthogonally inseparable from the first and/or second tracks.

Abstract: A method for manufacturing a bi-material sleeve is provided. The sleeve includes an annular outer sleeve and an annular inner sleeve bonded to each other. The bottom pouring of the outer sleeve is carried out in a casting space delimited by a wall of a first ingot mold and by an outer upwardly moveable wall of a second ingot mold concentric with the first. The moveable wall of the second ingot mold is raised so as to uncover the skin of the outer sleeve which has solidified thereagainst. The bottom pouring and the solidification of the inner sleeve are carried out in a casting space delimited by said skin and an inner stationary wall of said second ingot mold, the bonding of both sleeves being effected by diffusion between said sleeves. Forging and/or machining of one of said bonded sleeves are optionally carried out. A device for using this method and a sleeve produced by this method are also provided.

Abstract: A casting mould may include a soluble and substantially ring-shaped casting core forming a cooling duct and having at least one support which bears the casting core during a casting process. The at least one support may have a pin with a needle-like point configured to penetrate the casting core and fix it onto the support.

Abstract: A design for a casing of a large turbine is described with the casing including at least a front section, a middle section and an end section designed such that changes to the mold of the casing required to provide for a change in rotational speed to adapt the turbine to a different power grid frequency are limited to the mold for the middle section of the casing.

Abstract: A method of molding a platform opening includes the steps of providing a main body core and a platform core, with the main body core having a portion that forms a portion of the platform. The platform core has at least one side portion that will form a side opening. Molten metal is directed around the cores within a mold and solidifies. The cores are removed, leaving cavities where the cores were within the molten metal, and includes an opening in a side face formed by the side portion of the platform body core. Lost core components are also disclosed and claimed.

Abstract: A core for use in railcar coupler part casting processes is provided. The core has a hollow body, a top with a first opening defined therein, a bottom having a generally rounded wall, and second and third openings defined in the side wall of the body.

Abstract: A device that holds and replaces a casting plate in a continuous casting installation metallurgical vessel contains a detector-limit switch assembly that automatically moves a casting plate to the casting position or to the sealing position, depending on whether a replacement plate is on standby on the device or not. Casting plates used with the invention are provided with a metallic casing. The casting plates and metallic casing are configured to interact with the detector contained in the device.

Abstract: A Ni alloy layer is formed on a surface of a steel base on the side to be in direct contact with a molten aluminum alloy, and titanium carbide (TiC) is bonded in a particulate state to the surface of the Ni alloy layer. This makes it possible to provide a metal material having materially enhanced melting loss resistance without resorting to conventional techniques, such as the provision of a ceramic coating by PVD or CVD.

Abstract: A system for making a material having domains with insulated boundaries is provided. The system includes a combustion chamber, a gas inlet configured to inject a gas into the combustion chamber, a fuel inlet configured to inject a fuel into the combustion chamber, an igniter subsystem configured to ignite a mixture of the gas and the fuel to create a predetermined temperature and pressure in the combustion chamber, a metal powder inlet configured to inject a metal powder comprised of particles coated with an electrically insulating material into the combustion, wherein the predetermined temperature creates conditioned droplets comprised of the metal powder in the chamber, and an outlet configured to eject and accelerate combustion gases and the conditioned droplets from the combustion chamber and towards a surface such that conditioned droplets adhere to the surface to form a material having domains with insulated boundaries thereon.

Abstract: A system for making a material having domains with insulated boundaries is provided. The system includes a droplet spray subsystem configured to create molten alloy droplets and direct the molten alloy droplets to a surface, a spray subsystem configured to direct a spray of an agent at deposited droplets on the surface. The agent creates insulation layers on the deposited droplets such that the droplets form a material having domains with insulated boundaries on the surface.

Abstract: A system for forming a bulk material having insulated boundaries from a metal material and a source of an insulating material is provided. The system includes a heating device, a deposition device, a coating device, and a support configured to support the bulk material. The heating device heats the metal material to form particles having a softened or molten state and the coating device coats the metal material with the insulating material from the source and the deposition device deposits particles of the metal material in the softened or molten state on the support to form the bulk material having insulated boundaries.

Abstract: A soluble and substantially ring-shaped casting core may include a cooling channel in a piston having at least one inflow and at least one outflow. The casting core may form a closed ring and the inflow may be arranged directly adjacent to the outflow. The casting core may have a cross-sectional taper for forming a choke in the circumferential direction between the inflow and the outflow.

Abstract: To eliminate the need for a riser and for reduction in tilt speed and to enable molten metal contained in a mold to be pressurized by gas appropriately, a tilt type gravity molding device including a mold which can tilt between a fallen position and a standing position raised approximately 90 degrees from the fallen position, a pouring gate mold in which a pouring gate guiding the molten metal to a cavity of a molded article is formed, and a bowl-like member which stores the molten metal and pours the molten metal into the pouring gate in accordance with tilt of the mold includes closing means which is provided between the pouring gate and the cavity and can open and close the pouring gate, a gas inlet 9 which is provided at an upper portion of the mold at the standing position, prevents the molten metal from flowing out of the mold, and allows only gas to pass therethrough, and gas supplying means which allows high-pressure gas to be supplied to the gas inlet.

Abstract: Of the many embodiments provided, one embodiment is a drill bit mold assembly comprising: a mold having a bottom and at least one side; a core centrally disposed within the mold; and a filter disposed above the bottom of the mold and within a space formed between the at least one side of the mold and the core.

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 cores utilized in conjunction with a mold for casting a side frame of a railway car truck includes forming separate drag and cope portions of at least one pedestal core. The drag and cope portions of the pedestal core define an interior region of a pedestal of the side frame. The drag and cope portions are attached form a pedestal core for insertion into a mold.

Abstract: A method for manufacturing a bolster of a railway car truck includes providing a drag portion and a cope portion of a mold. In a main body section of the mold, a parting line that separates the drag portion from the cope portion is substantially centered between portions of the mold that define brake window openings in sides of the bolster. One or more cores are inserted into the mold and a molten material is poured into the mold to thereby case the bolster.

Abstract: A core assembly for forming the interior spaces of a railcar coupler knuckle has a first transition section between the C-10 portion of the core and the finger portion of the core. The first transition section has a first side, a second side, a third side and a fourth side and the first and second sides form the vertical axis of the first transition section and the third and fourth sides form the horizontal axis of said first transition section. The vertical axis of the first transition section has a height along a horizontal plane of the vertical axis of at least 2.5? and the horizontal axis of said first transition section has a width along a vertical plane of the horizontal axis of at least 0.925?.

Abstract: An interlock feature for railcar core comprises a lug on a first core, a slot on a second core, a first positive stop surface, and a second positive stop surface.

Abstract: A method of manufacturing a side frame mold for casting a side frame of a railway car truck includes forming a drag and a cope portion of a mold from a casting material to define an exterior surface of a drag portion and cope portion, respectively, of the side frame. The mold includes a portion for casting the pedestal jaw of the side frame. The drag and the cope portions are then cured.

Abstract: A method of casting a core includes the steps of preparing a first half of a corebox, preparing a second half of a corebox such that the parting line of a core formed from the first and second coreboxes runs along the vertical axis of the core.

Abstract: A multi-wall ceramic core for casting an airfoil with one or more internal cooling passages is made by preforming at least one fugitive core insert, then forming at least one core insert in-situ adjacent and fused to the at least one preformed core insert by introducing fluid fugitive pattern material into a composite core insert mold whereby the fugitive core inserts are integrally connected as a single composite core insert that includes features to form internal passage surfaces in the core when the composite core insert is removed. The composite core insert is placed in a core molding die cavity, and a fluid ceramic material is introduced into the die cavity to form the ceramic core body incorporating the fugitive composite core insert therein.

Abstract: A casting method and a casting device for a cast-metal object which are inexpensive and have a high degree of freedom are provided to cast plural types of cast-metal objects simultaneously. A cast-metal object is cast by using a casting device (10) including a mold structure (5) for forming a casting space capable of filling molten metal; and a runner (1) provided separately from the mold structure (5) for supplying molten metal into the casting space in the mold structure (5) by connecting the runner to the mold structure (5), wherein the runner (1) has a dividable structure, and the mold structure (5) has an assembly structure of a plurality of members.

Abstract: A nucleated casting apparatus including an atomizing nozzle configured to produce a droplet spray of a metallic material, a mold configured to receive the droplet spray and form a preform therein, and a gas injector which can limit, and possibly prevent, overspray from accumulating on the mold. The gas injector can be configured to produce a gas flow which can impinge on the droplet spray to redirect at least a portion of the droplet spray away from a side wall of the mold. In various embodiments, the droplet spray may be directed by the atomizing nozzle in a generally downward direction and the gas flow may be directed in a generally upward direction such that the gas flow circumscribes the perimeter of the mold.

Abstract: In said method, the mold (1), which includes a mold cavity (3A) defined by an ingot mold (2), a core (4) and a bottom (27), is arranged inside a vacuum-cast enclosure (5) including a means (9) of introducing molten metal at the upper portion thereof. A means (11A, 11?) for receiving and distributing molten metal, which is suitable for receiving the molten steel introduced into the vacuum-cast enclosure (5) and for redistributing the molten metal in the mold cavity (3A), is arranged at the upper portion of the mold cavity (3A). The molten metal is introduced into the enclosure (5) so as to form a first jet of molten steel (50) under a vacuum, in order to pour the molten metal over the receiving and distributing means (11A, 11?) and to form at least one second jet of molten steel (52) under a vacuum, which originates with the receiving and distributing means (11A, 11?) and terminates in the mold cavity (3A) so as to fill the mold cavity (3A) with molten metal.

Abstract: An exothermal weld mold includes a mold section with an integral cover portion, made as part of a single piece of material with the rest of the mold section. The mold section may be a mold half of a vertically split mold, or may constitute most of a half of the mold. The cover portion may be part of an integral cover that covers substantially all of a reaction chamber or crucible of the mold. The cover may have one or more vent holes, in the top and/or side of the mold. The cover may have a baffled passage for expansion of gases produced by reaction of the weld material, before the gases are expelled from the mold at an opening in the top or side of the mold. The passage may be a serpentine passage. A filter may be placed in the passage.

Abstract: A casting process for producing metal alloy castings, facecoats and apparatuses suitable for carrying out the process, and castings produced by the process. The casting process entails the use of a mold having a cavity with a continuous aluminum-containing solid facecoat on its surface. A molten quantity of a metal alloy is introduced into the mold cavity so that the molten alloy contacts the solid facecoat. The mold is then allowed to cool to solidify the molten alloy and form a cast product. During the casting process, aluminum in the solid facecoat diffuses into the cast product to form an aluminum-containing surface region at the casting surface. Following removal of the cast product from the mold, an alumina-containing scale grows on the casting surface as a result of oxidation of the casting surface region.