Abstract: A method for manufacturing a metal component using lost-wax casting is provided. The component is made of, for example, nickel alloy, with a columnar or monocrystalline structure with at least one cavity of elongate shape. The method includes creating a wax model of the component with a ceramic core corresponding to the cavity, creating a shell mold around the model, placing the mold in a furnace, with the base standing on the sole of the furnace, pouring molten alloy into the shell mold, solidifying the poured metal by gradual cooling from the sole in a direction of propagation.

Abstract: A core assembly for a casting system according to an exemplary aspect of the present disclosure includes, among other things, a core that includes a body and at least one hole formed through the body and a spacer that extends through the at least one hole. The spacer includes a stud portion and a chaplet portion configured to abut a surface of the body that circumscribes the at least one hole.

Abstract: A method of forming a component having an internal passage defined therein includes positioning a jacketed core with respect to a mold. The jacketed core includes a hollow structure formed from a first material, and an inner core formed from an inner core material disposed within the hollow structure. The method also includes introducing a component material in a molten state into a cavity of the mold, such that the component material in the molten state at least partially absorbs the first material from a portion of the jacketed core within the cavity. The method further includes cooling the component material in the cavity to form the component, and removing the inner core material from the component to form the internal passage.

Abstract: A core tie having a varying cross sectional diameter, a component including such a core tie, and a method of casting a hot gas path component for a turbomachine are provided herein. In an embodiment, the core tie includes a tie member having an axial length; and a cross sectional diameter which varies along the axial length of the tie member. A variation in the cross sectional diameter of the tie member positively secures a position of the core tie relative to the core.

Abstract: An apparatus for casting material has a die for receiving a compressive force, the die having a shaped-opening for receiving a die insert. The die insert has an exterior shape that is adapted to cooperate with and be received in the opening such that compressive forces impinging upon the die are focused upon the die insert such that tensile forces within the die and impinging upon the die insert are minimized.

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 for protecting a turbomachine from corrosion may include creating a first sand mold in a drag of a casting flask, coupling a cope of the casting flask to the drag, removing the runner pin and the at least one riser pin from the cope to expose a runner and at least one riser, respectively, and pouring a molten first material in the runner to cast a first component of the turbomachine. The method may further include removing the first sand mold, creating a second sand mold utilizing the first component in the drag, coupling the cope to the drag, removing the runner pin and the at least one riser pin from the cope to expose a runner and at least one riser, respectively, and pouring a molten second material in the runner to cast a second component of the turbomachine integral with the first component.

Abstract: A crankshaft is cast in a mold to define a plurality of pin bearing journals and a plurality of main bearing journals, at least one of each has a hollow section extending therethrough. A single core is positioned within the mold to form all of the hollow sections. The single core may include a cross-section defining an elliptical shape to form hollow sections having an elliptical cross-sectional shape to further reduce the weight of the crankshaft. The hollow sections are each positioned along a path that minimizes stress within the crankshaft. The path may include a non-linear path relative to a longitudinal axis of the crankshaft or a linear path angled relative to the longitudinal axis to bend or direct the hollow sections away from high stress regions of the crankshaft. The non-circular cross section of the core may spiral about its own axis to maximize mass reduction.

Abstract: Provided are methods of replacing drilling holes in castings by pre-tensioning sand cores. These methods are used in long cylindrical shaped sand cores in cold core box processes. The urethane sand core is placed in compression to increase the core strength during handling, placing inside of the mold. The pre-tensioned urethane sand core is set in a casting mold so as to form a cavity in the casting mold. The molten metal is poured to form the cavity inside of the casting. The pre-tensioned urethane sand core maintains its initial shape during casting.

Abstract: System and method for fusing a chaplet to a casting. The method includes placing the chaplet on an upper surface of a mold; distributing a heater around the chaplet such that the heater is not exposed to the casting; placing a core on the chaplet such that the mold and the core define a component of a machine; heating the chaplet with the heater to a predetermined temperature; and pouring the casting in the mold, around the core and the chaplet, when the chaplet is at the predetermined temperature.

Abstract: These inventions provide a method and an apparatus for setting a core used in a molding apparatus that produces flaskless molds, wherein the core-setting apparatus has a simple structure and the accuracy of the positioning of the core while setting it on the lower mold is improved. The inventions comprise: moving a first carrier 52 carrying a core-handling tool 51 which is holding the core 70 toward the cope flask 2 by means of a second carrier 53 when the cope flask 2 is located at the mold-stripping mechanism 12 being lifted to a lifted position by means of a flask-rotation mechanism 13; transferring the first carrier and the core-handling tool to the cope flask which is at the lifted position; lowering the cope flask 2, the core-handling tool 51, and the first carrier 52 by means of the flask-rotation mechanism 13 so that the core 70 comes close to or contacts the lower mold; and releasing the core 70 from the core-handling tool 51 to set the core on the lower mold.

Abstract: A core-setting apparatus and a method for setting the core in a lower mold used in a molding apparatus, wherein the core-setting apparatus has a simple structure and can maintain the core in the mold in a highly accurate position. The core-setting apparatus to set a core in the lower mold while the upper and the lower mold and a match plate are separated from each other after molding the upper and lower mold in a cope and drag flask includes a handling tool having a holding device and a rotatable rod, wherein the handling tool is rotatably supported by the rod, a carrier for transferring the handling tool, wherein the carrier supports the rotatable rod and is moved to or from a location above the lower mold, and an actuator for lowering and lifting the cope flask together with the carrier and the handling tool which are located above the drag flask, the actuator being mounted on the main body of the molding apparatus.

Abstract: A system for forming a seal slot in a shroud assembly has a first element having a longitudinally extending slot and a second element having a longitudinally extending slot for receiving a portion of the first element. The first element has a pair of opposed surfaces and the second element has a pair of opposed surfaces which are oriented at an angle to the surfaces of the first element. The second element may have a planar portion and a curved portion adjacent the planar portion for forming a slot which allows a flow of fluid to exit the slot at a desired angle.

Abstract: An investment casting process wherein the wax pattern tool (44) is flexible to facilitate removal of the tool from the cast wax pattern (52) even when the cast shape would otherwise require multiple pull planes. The flexible tool may include a flexible insert (42) precisely indexed to a surrounding coffin mold (40), and thereby to an enclosed ceramic core (10). Positioning pins (106) may extend from the flexible tool to make compliant contact against the core prior to a wax injection step. The surface of the resulting wax pattern may contain an engineered topography (36) replicated through the flexible surface from a master tool (12). The flexible tool may encase thermally conductive or magnetic particles (92), or other active device (96) such as a sensor or vibrator which is operable during wax injection.

Abstract: The invention relates to a casting tool for producing workpieces from light metal alloys. The system includes a positioning element, a core part, a first mold part structured to carry the positioning element and be movable toward the core part, and a core part support structured to support the core part. The system also includes at least one stop structured to limit movement of the front mold part toward the core part and to allow the positioning element to be introduced into the core part, whereby the positioning element holds the core part in a predetermined position for casting.

Abstract: A mold assembly device and method for assembling a semi-permanent mold assembly is disclosed, the mold assembly device includes a base die and a transfer frame, wherein the transfer frame is capable of transferring a core package to the base die and facilitates assembly of the transfer frame and the core package with the base die.

Abstract: A hollow jewelry pendant or bead formed by investment casting is disclosed. The method of manufacture consists of producing a mold usually consisting of metal, silicone or rubber containing a cavity for injecting an inner soluble core. A geometric lock is also formed as part of the injection core which will orientate the core both laterally and radially. This core will define the inner surface or hollow portion of the pendant as well as form the bail or hole through which the chain will slide. A second mold is produced usually consisting of metal, silicone or rubber containing a cavity into which the soluble core will be placed with the lock positioning the core so as to insure proper orientation. This is critical for consistent wall thickness and matching of design features. The cavity also allows for a wax or plastic material suitable for investment casting to be injected around the soluble core.

Abstract: A method for forming an investment casting core comprises cutting a patterned core precursor from refractory metal-based sheet. The cutting forms recast along the cuts. An oxide is grown on non-recast areas. The recast is substantially chemically removed but substantially leaving the oxide. The core precursor may then be shaped.

Abstract: A method of forming at least one concavity of a selected size and shape within a surface of an internal passageway of a metallic component comprises: depositing a ceramic-based material by a direct-write technique onto a ceramic core which is suitable for forming the internal passageway during a casting process to form the metallic component, wherein the ceramic-based material is deposited as a positive feature; heat-treating the deposited ceramic-based material; forming the metallic component by a casting process in which the ceramic core is incorporated into the casting, in a position selected as a desired position for the internal passageway; and then removing the ceramic core from the metal component after the casting process is complete, thereby forming the internal passageway, with the concavity contained within the surface of the passageway, said concavity formed by removal of the positive feature of the ceramic-based material.

Abstract: In a method of manufacturing a cylinder head having a partition plate for an intake port, there is prepared a partition plate having an intake-side distal end and a cylinder-side distal end. The partition plate is located in a core to form the intake port and molten metal is supplied to a periphery of the partition plate. After solidifying the molten metal, the core is removed. At least the intake-side distal end of the partition plate is located in an expansion-permit space that permits thermal expansion of the partition plate caused by heat of molten metal.

Abstract: The present invention is a method for casting a part having a complex shape or having a complex shape thereon. The method includes providing a pattern and securing at least one core to the pattern. A conformable material is located about the pattern and the core to create a complementary shape to the pattern and core in the conformable material. The pattern is removed and the core is left behind in the conformable material. The core leaves space, or an empty form, for a negative draw that cannot be formed in known casting methods. A mold is located adjacent the shaped, conformable material. A hardenable material is located between the mold and the shaped, conformable material and into the core. The hardenable material is allowed to harden and then it is removed. A cast part having a complex shape, or having a complex shape integrally formed with the part, results.

Abstract: A mold has outer mold parts and inserted molding material cores. Together, the parts and cores form a mold cavity. The inner cores of molding material are arranged in several layers one above the other. The inner cores are clamped in between the outer mold parts and a final covering core of mold material. A continuous clamping force is applied between the parts and cores. The mold cavity is formed by surfaces of the outer mold, surfaces of the inner cores and the covering core.

Abstract: A method for the production of a cast article having a small hole comprises the steps of setting a linear core member in a cavity of a metal mold, injecting a molten metal into the cavity, and drawing out the core member from the resultant-cast product to form a small hole. A linear core member having a surface film formed by surface coating or by subjecting to a surface treatment is used so that the surface film is partly or as a whole peeled off the linear core member upon drawing it from the cast product, thereby enabling the core member to be drawn from the inside of the cast product. Alternatively, the linear core member is so constructed as to elastically deform in the drawing direction upon drawing it from the cast product to have a diameter smaller than the original diameter.

Abstract: The specification and drawings describe and show an embodiment of and method of forming a liquid flow through heat exchanger structure cast in a metal matrix composite. The composite comprises a preform reinforcement material infiltrated with molten metal. The composite reinforcement material is injection molded around the heat exchanger structure allowing for intimate contact between the composite and structure. The composite formed has a specific coefficient of thermal expansion to match active heat-generating device(s) mounted thereon. The present invention allows for enhanced thermal and mechanical properties by eliminating voids or gaps at the composite to heat exchanger structure interface, these voids or gaps being present in prior art fabrication methods or induced by usage due to thermal cycling of prior art composites.

Abstract: A method for the production of a cast article having a small hole comprises the steps of setting a linear core member in a cavity of a metal mold, injecting a molten metal into the cavity, and drawing out the core member from the resultant cast product to form a small hole. A linear core member having a surface film formed by surface coating or by subjecting to a surface treatment is used so that the surface film is partly or as a whole peeled off the linear core member upon drawing it from the cast product, thereby enabling the core member to be drawn from the inside of the cast product. Alternatively, the linear core member is so constructed as to elastically deform in the drawing direction upon drawing it from the cast product to have a diameter smaller than the original diameter.

Abstract: A method for the production of a cast article having a small hole comprises the steps of setting a linear core member in a cavity of a metal mold, injecting a molten metal into the cavity, and drawing out the core member from the resultant cast product to form a small hole. A linear core member having a surface film formed by surface coating or by subjecting to a surface treatment is used so that the surface film is partly or as a whole peeled off the linear core member upon drawing it from the cast product, thereby enabling the core member to be drawn from the inside of the cast product. Alternatively, the linear core member is so constructed as to elastically deform in the drawing direction upon drawing it from the cast product to have a diameter smaller than the original diameter.

Abstract: An apparatus and associated method of manufacture for coupling a receiver and a transmitter to a single antenna feed horn so as to allow for the simultaneous transmission and reception of co-polarized signals, such as in a radio frequency communications system, are provided. To separate the two co-polarized signals of different frequencies, the apparatus comprises a waveguide junction, a first filter tuned to the transmit signal frequency, and a second filter tuned to the receive signal frequency. The apparatus may be manufactured using low-cost reusable-mandrel casting techniques.

Abstract: A method to suppress displacement of the core during casting when making hollow blades by applying the lost wax method using a core. A wax pattern is made which comprises a core and a layer of wax covering the core. Then at least one pin of the same material as the blade is inserted into the wax layer such that this pin engages the core and part of the pin projects from the outer surface of the wax layer, after which, with the portion of the pin which projects from the outer surface of the wax layer being held in a casting mold, the wax is removed, followed by casting.

Abstract: A wax article pattern having a cavity corresponding to a cavity in a metal article is provided. The cavity in the wax article pattern is filled with a slurry of ceramic core material. The slurry of ceramic core material is solidified to form a core. The wax article pattern is enclosed by ceramic mold material. The ceramic mold material is solidified to form a mold. The wax pattern is removed from the mold to leave an article mold cavity. The article mold cavity is filled with molten metal which is solidified to form the metal article. A passage in the metal article may be formed by a pin which extends from the wax article pattern into the cavity in the wax article pattern and is enclosed by the slurry of ceramic core material.

Abstract: A core forming mold having at least three regions is provided and a molding sand is supplied into the core forming mold. The molding sand is hardened by an amine gas, to obtain a molding core having at least one region which has a diameter smaller than that of other regions. An iron casting mold is provided having a molding cavity therein, such that the molding core is positioned within the molding cavity of the iron casting mold. A molten iron is cast within the iron casting mold to entirely enclose the molding core.

Abstract: A three-way wet barrel fire hydrant includes an enlarged intermediate barrel section, which effectively reduces pressure loss in the fire hydrant. The hydrant barrel is formed by an improved sand molding process which requires the mold parting line of the barrel to be selected to coincide with the centerline of the upper nozzle opening. In this manner, a pattern which forms the sand mold may be removed cleanly from the molding sand, thereby eliminating the need of multiple side cores during the casting process.

Abstract: The tapered core/shell lock includes notches which, in conjunction with protrusions from the shell mold, prevent axial slip of the core main body. In addition, the core/shell lock provides a tapered core print area which is much larger, and extends further into the shell mold, then the conventional "T" bar core/shell lock. By increasing the axial length of the core print area, shifting at the tip of the core main body is reduced, while tapering of the core print eliminates the need to lacquer slip the end of the core/shell lock, eliminating addtional sources of core shift.

Abstract: A sand core adapted for high pressure casting is formed by a core body and a support pin to be connected to the core body. The support pin is provided with one end portion to be embedded in said core body and the other end portion projected outwardly from the core body. A connecting means is formed to the embedded portion so as to integrally connect the core body and the support pin and a support pin positioning and supporting means is formed at the projecting portion of the support pin. Positioning pins extending from a core formation mold are engaged with the positioning and supporting means so that the embedded end portion of the support pin is positioned in the cavity of the core formation mold. The cavity is filled with core sand whereby the embedded one end of the support pin is supported to integrally form the support pin and the core body. The sand core is dipped in a slurry including a sand core coating material and then heated and dried.

Abstract: The ceramic core is located within the ceramic mold by the insertion of recrystallized alumina pins through the wax encasing the core prior to encasing the whole in a ceramic slurry; on the subsequent removal of the wax, the molten metal, i.e. superalloy, is injected into the resulting space; the recrystallized alumina pins remain intact during the casting process hence substantially increasing the success rate of achieving accurate core locating during casting solidification.

Abstract: A reinforced tubular core for casting gas turbine engine blades with cooling air passages therein is disclosed. A method of casting is also disclosed in which the blades are directionally solidified to produce columnar grained or single crystal blades and in which non-linear passages can be produced. The problem in producing such articles is that the moulds and cores used in the casting process are held at temperatures in excess of 1500.degree. for long periods and presently used Silica cores deform during the process. Stronger cores of Alumina or Silicon Nitride cannot be easily bent were believed to be non-leachable from the casting. The present invention provides a core having a tubular silica sheath with a solid alumina rod inside it for support. The sheath can be bent and the straight alumina rods can be inserted from opposite ends of the sheath.

Abstract: The present invention provides a method for manufacturing a thin-walled ceramic casting mould which is particularly suitable for casting directionally solidified articles in which rapid cooling of the cast material is required. The mould is transfer moulded around a disposable pattern material and includes an integral core. The mould has an outer wall thickness of the order of 0.5 mm to 2.0 mm. The mould and core may be made of the same or different ceramic materials chosen for their strength or thermal conductivity. The method further provides for a series of high temperature disposable supports embedded in the disposable pattern material, providing support for the outer wall of the mould during the firing process. The disposable supports are disposed of at a temperature at which the mould has acquired self-supporting strength.

Abstract: A process is provided for pressure casting a piston with a crown insert and a cavity. The process comprises casting crown down in a mould and, before casting, placing in the mould means for forming a crown insert and a soluble salt core forming a cavity in the piston. The salt core is held by the crown insert means to position the salt core in the mould so preventing the salt core moving during pressure casting.

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: A novel casting method is provided which includes a shell mold having a cope and a drag, which abut together along substantially planar mating surfaces and define a casting cavity between the cope and drag. At least one core is positioned within the casting cavity and includes at least one and preferably two crush pads each having a cam surface. As the cope is positioned onto the drag, the cope engages the crush pad cam surfaces and cams the core flatly against the shell 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: A Vacuum-sealed moulding process for casting of materials comprises formation of sand moulds in the absence of a pattern plate and with cores supported in the mould by suction. Handling apparatus for producing the mould on a vibratory vacuum table is disclosed and this incorporates a pneumatic sand transfer apparatus delivering a predetermined quantity of sand to the mould box.

Abstract: The present invention provides means for the improved positioning of a strongback in a pattern mold for formation of expendable patterns thereon. Investment casting molds formed around the assembly of strongback and patterns are characterized as having the strongback precisely and reproducibly suspended therein. Articles, such as turbine blade halves, cast in such investment molds have mating surfaces in close dimensional relationship and can be bonded one to any mating other to form a finished product.In particular, a strongback having bonding locators near the opposite ends thereof is provided with additional locators to be used in suspending the strongback in the pattern mold. According to the invention, these pattern mold locators are colinear with and in close proximity to the bonding locators and are engaged by locating means in the pattern mold for establishing precise positioning of the strongback therein.

Abstract: The present invention provides a method for improved positioning of a strongback in a pattern mold for formation of expendable patterns thereon. Investment casting molds formed around the assembly of strongback and patterns are characterized as having the strongback precisely and reproducibly suspended therein. Articles, such as turbine blade halves, cast in such investment molds have mating surfaces in close dimensional relationship and can be bonded one to any mating other to form a finished product.In particular, improved positioning of the strongback in the pattern mold is achieved by suspending the strongback from the bonding locators by expendable locating means; that is, locating means which are incorporated into the patterns formed on the strongback surfaces. The use of expendable locating means enables the bonding locators to also serve as locators for positioning the strongback in the pattern mold and essentially eliminates errors in strongback positioning due to tolerances associated therewith.

Abstract: A method is disclosed for producing cast metal parts having smooth surfaces held to close dimensional tolerances, eliminating the need for machining. The method includes making a core box and pattern to closer tolerances than the finished part, producing a sample core and mold using sand of predetermined characteristics under regulated conditions. The sample core is precisely assembled with the sample mold and gauged. Thereafter, a prototype part is cast at a controlled temperature and cooled for a controlled time. The dimensions of the prototype part are compared with desired dimensions and the core box and pattern are modified where required. They are subsequently used to make production cores and molds formed from same sands under same conditions previously employed. The production cores and molds are accurately assembled and gauged and production parts cast at the same temperature previously used and are cooled as before.

Abstract: A method of inserting a core in a sand mold wherein the sand mold is provided with a cavity for receiving the core, and, during the insertion of the core in the cavity, the sand around the core is compressed by an element or, if the core print is provided with a retaining projection, a further projection on the core print is provided for compressing the sand around the cavity in the sand mold which receives the retaining projection.