Abstract: The invention relates to a method for producing a cooled cast part (1) for a thermal turbo machine by using a known casting process. Between a wax model (10) of the cast part (1) and a ceramic core (6), a wax seal (8) is applied by hand above a step (7), only on an additional shoulder (9). The material that is created during the casting process at this point by the shoulder (9) and the wax seal (8) can be ground off without causing rough areas on the step (7) to form. This simplifies the welding or soldering of a cooling plate to the step (7).

Abstract: When a waste wax composition containing a filler is treated so that the filler is recovered and thus reclaimed, almost all the impurities coming from the lost wax casting mold may be removed, thereby recovering and thus refining at a high purity, a filler of a lost wax composition. Crude reclaimed filler is first produced by dissolving and dispersing a waste wax composition in an organic solvent, and separating a dissolved wax phase from a solids/wax-containing fraction. The crude reclaimed filler is then dispersed in an aqueous alkaline solution, so as to dissolve and thus remove alkali-soluble impurities, followed (or preceded) by dispersion in an acidic aqueous solution so as to dissolve and thus remove acid-soluble impurities.

Abstract: A microwave-based process for dental casting includes the use of microwave radiation to obtain burnout of a wax pattern from an investment mold. Phosphate-based, thermal investment materials have been found suitable for use in the process.

Abstract: A casting includes a heat transfer surface having a plurality of cavities. The plurality of cavities include a density of at least about 25 cavities per square centimeter to about 1,100 cavities per square centimeter resulting in increased surface area and therefore enhanced heat transfer capability. A mold for forming a pattern for molding the casting includes a surface defining a portion of a chamber to which are attached a plurality of particles having an average particle size in a range of about 300 microns to about 2,000 microns.

Abstract: A vent-forming apparatus for use in metal casting comprises a gas-permeable membrane with a lead-in tube attached to one surface and a breather tube attached to the opposite surface. The vent-forming apparatus may be used to create independent vents in the walls of shell-type molds used in the ceramic shell casting process for lost wax casting of ferrous and non-ferrous alloys. These vents exhaust gasses in the mold cavity to the atmosphere. The vent-forming apparatus also may be used in solid mold investment casting methods or in any other casting method in which venting is desirable or necessary.

Abstract: A casting includes a heat transfer surface having a plurality of cavities. The plurality of cavities include a density of at least about 25 cavities per square centimeter to about 1,100 cavities per square centimeter resulting in increased surface area and therefore enhanced heat transfer capability. Also disclosed is a mold for forming a pattern for molding the casting. The mold includes a surface defining a portion of a chamber to which are attached a plurality of particles having an average particle size in a range of about 300 microns to about 2,000 microns.

Abstract: A process for producing structural elements, preferably prototypes, in which a “lost” model, i.e., positive model, of the structural element is produced in a first step and the model is subsequently cast with a molding compound to produce a negative mold. The mold is then used for manufacturing the structural element, preferably a prototype, by casting. The model is cast and/or filled with the molding compound in a plurality of successive steps and the position of the model relative to a reference plane is changed in each of the individual steps of casting or filling.

Abstract: A microwave-based process for dental casting includes the use of microwave radiation to obtain burnout of a wax pattern from an investment mold. Phosphate-based, thermal investment materials have been found suitable for use in the process.

Abstract: An implantable prosthesis having porous textured surface regions and methods for making the same provide improved prostheses and prosthesis manufacturing methods. The implantable prostheses contain one more bead preforms that are secured to the metallic prosthesis components during the casting process to form porous textured surface regions in desired areas of the prostheses.

Abstract: A spray forming pattern of a first metal having a melting point at a first temperature is formed. The spray forming pattern has a surface defining a cavity that has the shape of a master pattern. Steel particles having a carbon content in the range of 0.01-0.9% by weight are sprayed onto the spray forming pattern to form a deposit on the spray forming pattern. The deposit has a thickness of at least 0.5 inches and the temperature of the steel particles increases as the thickness of the steel deposit increases. The spraying conditions are controlled so that the steel particles coming into contact with the spray forming pattern results in a surface temperature of the spray forming pattern of less than about 80.degree. C. The deposit and the spray forming pattern are heated to a second temperature, which is higher than the first temperature, to melt the spray forming pattern from the deposit. The resulting deposit has the general shape of the master pattern.

Abstract: A process for fabricating a hollow or partially hollow article, such as a jewelry ring, comprises producing a first mold having an inner cavity shaped in accordance with the external shape of the article to be produced. A second mold is produced for forming a wax core insert which is inserted in the first mold cavity for forming the hollow region of the article. The second mold has an inner cavity formed in the shape of, but slightly smaller than, the external shape of the article. The cavity of the second mold has holes which form spacer pins on the wax core insert. The wax core insert is then placed in the cavity of the first mold and is maintained in a precise, predetermined position by the spacer pins. During waxing of the article, a plastiwax is introduced into and fills the cavity of the first mold, completely surrounding the wax core insert. The plastiwax hardens and is removed from the first mold cavity with the wax core insert.

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 golf ball mold is prepared by inserting a dimpled hemispherical male die into a chamber in a frame, admitting hot liquid wax into the chamber, cooling and curing the wax to form a wax shape, covering the wax shape with a mix slurry of ceramic particles and a binder, drying and curing the slurry to form a ceramic shell around the wax shape, removing the wax shape from the ceramic shell, casting a molten metal into the ceramic shell, cooling and solidifying the metal to form a mold half, and removing the ceramic shell from the mold half. The mold is improved in molding precision, durability and cost.

Abstract: Housing frames for use in electromechanical machines may be advantageously produced using a novel pattern form in a lost foam casting process. The pattern form is made from a cast dissolvable material, and is configured to permit easy modification prior to casting. The pattern form may be adapted to produce footed or footless housing frames, or housing frames of various axial lengths. In addition, the frame area on which a conduit box will be attached can be easily modified prior to casting. After the pattern form has been modified, it is placed in a casting medium of dry particulate material, such as sand. Upon contact with molten metal, the pattern form vaporizes. The molten metal fills the space where the pattern form had been, assuming the desired shape. After the molten metal has cooled to rigidity, the resulting housing frame can be removed from the casting medium.

Abstract: An article has a thin wall portion with a thickness of 0.060 inches or less, a width of at least four inches, and a height of at least six inches. In order to cast the article, a pattern having a configuration corresponding to the configuration of the article is covered with a coating of wet ceramic material. In addition, a reinforcing pattern, which is spaced from the portion of the article pattern having a configuration corresponding to the thin wall portion of the article, is covered with the wet ceramic material. Space between the article pattern and reinforcing pattern is filled with the wet ceramic material. A combined mold structure and reinforcing structure are formed by drying the wet ceramic material. The article pattern is removed from the mold structure to leave a mold cavity. Molten metal is conducted into the mold cavity.

Abstract: A process for fabricating a hollow or partially hollow article, such as a jewelry ring, comprises producing a first mold having an inner cavity shaped in accordance with the external shape of the article to be produced. A second mold is produced for forming a wax core insert which is inserted in the first mold cavity for forming the hollow region of the article. The second mold has an inner cavity formed in the shape of, but slightly smaller than, the external shape of the article. The cavity of the second mold has holes which form spacer pins on the wax core insert. The wax core insert is then placed in the cavity of the first mold and is maintained in a precise, predetermined position by the spacer pins. During waxing of the article, a plastiwax is introduced into and fills the cavity of the first mold, completely surrounding the wax core insert. The plastiwax hardens and is removed from the first mold cavity with the wax core insert.

Abstract: A flexible and resilient positive pattern is made for a desired high temperature metal or ceramic part such as a gas turbine impeller having a complex geometry with walls defining undercut spaces, and the pattern with flexible walls is dipped into a ceramic molding media capable of drying and hardening. The pattern is removed from the media to form a ceramic layer on the flexible pattern, and the layer is coated with sand and air dried to form a ceramic layer. The dipping, sanding and drying operations are repeated several times to form a multiple layer ceramic shell. The flexible wall pattern is removed from the shell, by partially collapsing with suction if necessary, to form a first ceramic shell mold with a negative cavity defining the part and to provide for reusing the pattern. A second ceramic shell mold is formed on the first shell mold to define the back of the part and a pour passage, and the combined shell molds are fired in a kiln.

Abstract: The pattern material with substantially spherical filler particulates is used to produce investment cast components with improved surface quality, reduced finishing costs, and reduced core breakage. The pattern material comprises substantially spherical particles within the particle size range of about 10 microns to about 70 microns particle diameter, the use of which reduces the number of random, localized surface depressions and pits to improve pattern surface texture and uniformity. Patterns so formed inpart the same improvements to the surface of subsequent investment cast components. The resulting castings exhibit improved as-cast surface finish and reduced random, localized surface pitting, thereby reducing or eliminating expensive post casting surface finishing operations. Moreover, the spherical morphology of the filler particulates reduces injection pressures to fill a pattern die cavity as compared to non-spherical filler particulates.

Abstract: A method for casting a turbine bucket with at least one surface cooling hole. The method comprises positioning at least one preformed spacer device on a core, where the preformed spacer device is formed of ceramic materials and comprises opposed end plates and at least one interconnecting crossover pin connecting the end plates; forming a layer of temporary material, such as wax, over the core and around the at least one preformed spacer device; forming a shell mold over the layer of temporary material to cover it, the core and the at least one preformed spacer device. The shell mold is maintained stably positioned and spaced from the core by the at least one preformed spacer device, which connects and maintains the shell mold and the core as a stable body. The wax is removed to form a casting space for the turbine bucket between the shell mold and the core and around the at least one preformed spacer device.

Abstract: A wax-like substance mainly consisting of a saturated chain hydrocarbon, in which a weight ratio (C/H) of carbon and hydrogen is 5.839-6.018, a total weight % of the carbon and the hydrogen is 98.5%-100%, a number-average molecular weight (Mn) is 3.0.times.10.sup.3 -1.0.times.10.sup.4, a weight-average molecular weight (Mw) is 1.0.times.10.sup.4 -5.0.times.10.sup.4 and Mw/Mn is 1.0-5.0. In the case of using it for carving and casting, for example, the wax-like substance can be repeatedly used, and has excellent workability. Moreover, the wax-like substance provides easy dewaxing from a mold material. In other words, it provides convenient use. In addition, after a master model is made by processing the wax-like substance and covered with a mold material, it is dewaxed. Molten metal is poured into the mold material, and a shaped article is produced by cooling and solidifying the mold material where the molten metal has been poured.

Abstract: Methods and compositions for forming shells for investment casting and methods for casting metal articles using the shells are described. One embodiment of the method comprises serially immersing a pattern in at least one, and perhaps several different slurries, each of which slurries comprises refractory material and from about 0 to about 30 volume percent inorganic binder. This forms a facecoat and plural refractory backup layers about the pattern, the facecoat and at least one backup layer defining a shell. The facecoat and/or the shell is then infiltrated with a binder. Infiltrating the shell with a binder is a key feature of the present invention. Infiltration refers to any process whereby a binder can be introduced into the facecoat and/or the subsequent layers built up about the shell.

Abstract: A production process of a wax pattern having a core, which is used for casting a product having a complicated hollow portion, comprising the steps of: producing two or more wax shells each having a contour of an external surface of a desired casting; and combining the wax shells with a core to obtain a wax pattern having a hollow portion between the wax shells and the core. Using the method, the occurrence of breakage of the core during dewaxing or production of the pwax pattern is extremely reduced, and a lowering in yield rate due to the breakage of the core is remarkably ameliorated.

Abstract: An investment casting shell is made by providing an investment casting pattern that defines a cavity and filling the cavity with a fluid. The fluid is sealed within the cavity and a ceramic material is applied to the exterior of the pattern. The ceramic-encased pattern is heated and the pattern and fluid are removed from the ceramic.

Abstract: The instant invention contemplates a process for manufacturing jewelry including the steps of: (a) creating a photographic negative from a computer-generated image; (b) exposing the back side of a polyester backed soft photopolymerizable resin sheet to ultra-violet radiation thereby causing photopolymerization to a predetermined depth corresponding the exposure duration; (c) masking the negative over a "soft" photopolymerizable resin; (d) irradiating the unmasked resin with ultraviolet radiation; (e) chemically removing the non-photoset resin from the photopolymer resulting in a positive three-dimensional likeness of the object to be cast; and (f) creating a final negative mold using the positive three-dimensional likeness via a "lost-wax" type process.

Abstract: A mold assembly and sprue configuration for dental investment casting includes a ring shaped casing, a base and a cover all made of resilient plastic material and fictionally engaged with each other. The base includes a raised neck having a top surface with a sighting bead for use in mounting wax forms on the sprue, positioned within the casing. The sprue includes a post for engaging a blind bore in a hub of the base. The cover includes a downwardly extending plug which extends into the body of the casing, and a curved lip with recess for facilitating the pouring of investment solution into the mold. The sprue has three spokes and a ring which are all triangular in cross-section to reduce the amount of metal needed in the precision casting to be made with the invention and also to provide a convenient flat upper surface for mounting wax forms to the sprue.

Abstract: Steel bit bodies are manufactured in a production process that employs polystyrene patterns in a lost foam casting process. The patterns are machined to permit the formation of complex shapes that cannot be reproduced in simple patterns that are extractable from reusable, two-piece pattern molds or dies. The patterns are machined from a billet material according to a basic, programmed, five-axis machining process to form multiple copies of a reproducible complex pattern body. The process is modified to produce multiple copies of a modified design. Machining the complex patterns and producing variations by changing the machine program permit multiple bit patterns of variable forms to be produced without need for building an intermediate, reusable pattern mold that would require multiple mold pieces, thus eliminating the associated time and expense required in the creation of a new pattern mold for each variation of the bit design.

Abstract: A method of manufacturing gem decorated articles, typically jewelry, includes the steps of: using a first mold which has a mold cavity with one or more gem portions for receiving one or more gems and duplicates a model of the article; positioning one or more gems in the mold gem portion(s) of the mold; forming a temporary bond between the gem(s) and the mold gem portion(s) of the mold to maintain the gem(s) in place in the mold gem portion(s) during formation of a wax model including the gem(s); introducing a molten, hardenable wax material into the mold; cooling the wax material to form a wax model reproduction of the article with the gem(s) set therein; ending the temporary bond between the gem(s) and the mold gem portion(s) of the mold; removing the wax model with the set gem(s) from the mold; applying an investment material about the wax model with the set gem(s) and hardening the investment material to form a second mold; removing the wax material from the second mold; introducing a molten metal into the

Abstract: The investment casting method uses the lost wax method and involves using a model to form a wax piece in the desired shape such as the shape of the snap element or the shape of two hinge halves, making a tree out of a multitude of the wax pieces, adding slurry and heating to create hard material having spaces shaped like the wax parts and then pouring molten casting material into the spaces in a vacuum environment.

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: Method of multi-color jewelry items production is based on a simultaneous casting of two metal alloys of different colors (yellow-red, white-yellow, etc.), as well as two different metals, with a purpose of obtaining jewelry art-works of high-quality and unique artistic impression. To serve that purpose, the following apparatus has been constructed: rubber base with two inlets, two-chamber ceramic crucible with two identical outlets, and a model of the jewelry item with two sprues connected to two separate tree stems, with each sprue connected to a separate stem thus ensuring flow of different colors or different metals. Simultaneous casting of two different metal alloys of different colors in two separate chambers of crucible is achieved by using a specially constructed two-head torch. Usage of this invention in the process of jewelry work casting ensures a unique natural effect of smooth transition from one color to another in a jewelry piece (ring, brooch, pendant, charm, etc.

Abstract: Methods are provided for producing investment cast articles, such as orthopedic implants, or portions thereof, having at least a partially textured surface that is formed during casting of the article. In an exemplary method, a textured metal casting is produced by creating a heat destructible pattern and spraying the pattern with a texturing material to cause the texturing material to form a textured surface on at least a portion of the pattern. In another embodiment, a textured template is pressed against a heat softenable pattern to provide a textured pattern. With respect to each of these methods, a shell is the created around the textured pattern to form a mold, and the pattern is removed from the shell. Molten metal is introduced into the mold and allowed to harden, after which the mold is removed.

Abstract: A method of making a custom, bioimplantable article, such as a joint prosthesis component, is provided using computer aided design, rapid prototyping, and investment casting techniques. The method includes the creation of a data file, using computer aided design (CAD) techniques, that defines a negative or a shell of a portion of a bioimplantable article that is custom configured for a specific arthroplasty patient. The data file for the shell of the custom portion of the bioimplantable article is accessed by a rapid prototyping machine, such as a three-dimensional printer, to create a mold that corresponds to the shell. The mold, generally a heat-resistant ceramic, is positioned relative to an existing, non-custom representation of a bioimplantable article to define a hybrid component. A heat-resistant shell is formed around the hybrid component and the non-custom representation of a bioimplantable article is removed from the shell using heat.

Abstract: Methods are provided for producing investment cast articles, such as orthopedic implants, or portions thereof, having at least a partially textured surface that is formed during casting of the article. In an exemplary method, a textured metal casting is produced by creating a heat destructible pattern and spraying the pattern with a texturing material to cause the texturing material to form a textured surface on at least a portion of the pattern. In another embodiment, a textured template is pressed against a heat softenable pattern to provide a textured pattern. With respect to each of these methods, a shell is created around the textured pattern to form a mold, and the pattern is removed from the shell. Molten metal is introduced into the mold and allowed to harden, after which the mold is removed.

Abstract: A process for fabricating a hollow or partially hollow article, such as a jewelry ring, comprises producing a first mold having an inner cavity shaped in accordance with the external shape of the article to be produced. A second mold is produced for forming a wax core insert which is inserted in the first mold cavity for forming the hollow region of the article. The second mold has an inner cavity formed in the shape of, but slightly smaller than, the external shape of the article. The cavity of the second mold has holes which form spacer pins on the wax core insert. The wax core insert is then placed in the cavity of the first mold and is maintained in a precise, predetermined position by the spacer pins. During waxing of the article, a plastiwax is introduced into and fills the cavity of the first mold, completely surrounding the wax core insert. The plastiwax hardens and is removed from the first mold cavity with the wax core insert.

Abstract: A rigid bar (or segment) on which stones will be at least partially supported is positioned in a rubber mold for creating a wax pattern of the jewelry, injecting wax to form a wax model of the jewelry including the metal bar to fit into an incision in the stones. The model with the metal bar forms the invisible pre-set stone mount. Stones are then placed into set position in the wax pattern on opposite sides of the metal bar. Once the setting is complete, the jewelry is created using known "lost-wax" method of manufacturing jewelry.

Abstract: A method of making a wax pattern by using a dental gypsum model is provided, which comprises the steps of applying a release agent on said gypsum model, coating on the thus applied surface a coating material which leaves no ash upon incinerated at 700.degree. C., and applying a wax melt on said surface. When the wax melt is applied on the gypsum model, the wax is in no direct contact with the release agent, and it is unlikely that gaps may be formed between the wax pattern and the gypsum model or a pad of the wax pattern may warp; that is, the additional operation so far needed for correcting such warpage can be dispensed with, so making precise casting possible. In addition, the presence of the release agent enables removal of the wax pattern to be done as conventional. Furthermore, when the thus removed wax pattern is invested in a investment material to incinerate the wax pattern, no ash of the above coating material remains in the cavity, so that metal can be cast with no defect.

Abstract: An investment casting process which includes: attaching a gate to a pattern made of a plastic to form a pattern assembly; forming a mold by applying a plaster slurry on an outer surface of the pattern assembly; dissolving and removing the pattern assembly in the mold by applying an organic solvent; burning the mold from which the pattern has been removed; casting by pouring a molten metal into the burned mold; and breaking the mold to take out a cast product.

Abstract: In a method of investment casting a turbine nozzle which includes an outer band, an inner band and an airfoil section extending between the inner and outer bands, an improvement including shaping a temporary wax form, and external shell and internal core components used in casting such that during pouring of molten metal into a space created by removal of the wax form, shell material lies on opposite sides of an outer fillet connecting the outer band to the airfoil section. The resulting gas turbine nozzle includes first and second horizontally oriented ribs extending about interior peripheries of the airfoil section vertically adjacent the outer and inner band fillets.

Abstract: Compression and distortion on a wax pattern during curing are eliminated by employing a thermochromatic dye which changes color when investment material sets. By monitoring the dye, the set investment material can be removed from the assembly before curing, eliminating compression forces on the wax pattern from the exothermic curing process expanding the investment material against the constraints of the assembly.

Abstract: The golf club head comprises a head body which defines the front striking face of the club head. Disposed within the head body is a ceramic insert which defines the rear face of the club head. The head body is cast about the insert in a manner wherein the insert is partially encapsulated by the head body and rigidly captured therewithin.

Abstract: The instant invention contemplates a process for manufacturing jewelry including the steps of: (a) creating a photographic negative from a computer-generated image; (b) masking the negative over a photopolymerizable resin backed by a rigid substrate; (c) irradiating the unmasked resin with ultraviolet radiation; (d) removing the unpolymerized resin from the photopolymer, using a washing agent such as water, resulting in a positive three-dimensional likeness of the object to be cast; (e) placing the resulting etched resin plate into a container and pouring tooling resin into the container thereby creating a plug bearing the negative impression of the jewelry item to be created; (f) inserting the tooling resin plug into a jewelry item mold having an empty sleeve which receives the plug resulting in a completed jewelry mold; (g) filling the completed mold with plastic resulting in a plastic model of the jewelry item to be created; (h) using the plastic model in a "lost wax" casting process to create an individua

Abstract: A wax shell covered pre-formed core body is provided, the thickness of the wax shell corresponding to the desired thickness of the wall structure. A ceramic shell is formed about the wax shell. The wax shell is removed by melting the wax, thereby to form an opened gap between the ceramic shell and the core body. Molten metal is cast into the opened gap, thereby to form the wall structure extending about the core body and at the sole, while forming and maintaining port structure through the wall structure and spaced from the sole, and allowing the wall structure to solidify to form the head. The ceramic shell is removed from the wall structure, and the core body is removed from the interior of the solidified head, and via the port structure.

Abstract: The process consists of starting from a lace or embroidery in cotton or synthetic fibers, applying to the model wax, resins or varnishes capable of increasing the size, then coating the model with gypsum and then introducing the coated model into a furnace. The heat destroys the model and leaves a cavity which has the shape of the model. The precious metal is introduced into the cavity in the molten form. Finally the article is allowed to solidify and the gypsum is crushed. The decorative article may be used for necklaces, bracelets or similar materials.

Abstract: A method of forming a cast orthopaedic implant having a porous surface layer is disclosed. The method includes placing a porous layer on a wax replica of the implant such that a portion of the pores of the layer are filled with the wax material. The wax replica and porous surface layer are coated by a ceramic material consistent with investment casting technology. The ceramic material fills the remainder of the pores of the porous layer. After the ceramic material is solidified, the wax material is melted away leaving a cavity within the ceramic material. The pores once filled by wax are now exposed and extend into the cavity. A molten metal is poured into the cavity and partially melts the exposed porous layer to form a melt bond with the molten metal. When the metal is cooled, the ceramic material is stripped away exposing the portion of the porous layer previously filled with the ceramic medium.

Abstract: A method for producing composite materials by forming one material in a die cavity such that another material can be forced into the same die cavity and infiltrate the spaces in the first material. A method for producing a composite comprising the steps of injecting reinforcement material in a binder or suspension into a die cavity; burning off or removing the binder or suspension such that the reinforcement material remains in the die cavity; injecting liquid metal into the same die cavity such that it infiltrates the reinforcement material; solidifying the liquid metal; and removing the metal infiltrated composite material from the die cavity. An apparatus comprised of a die and a die cavity disposed inside the die. The apparatus is also comprised of a first port extending from the die cavity to the surface of the die through which reinforcement material in a binder is injected into a die cavity.

Abstract: A method of making a ceramic shell mould for casting includes making a pattern having an internal cavity in two parts from a disposable material, glueing the two parts together to complete the hollow pattern, filling the internal cavity with a ceramic material, and simultaneously or subsequently forming a shell of a ceramic material around the filled pattern. The pattern can then be eliminated to obtain a casting mould with an inner core made in situ.

Abstract: In the present invention, a Collector's Model Disintegrator Pistol (CMDP) is formed from a pair of fight side and left side metal castings according to the investment or "lost wax" casting process. Preferably the left and right hand pistol sections are formed of suitable ornamental bronze, with a wide variety of possible bronze compositions being usable, depending upon cost and desirability of a particular finish. The bronze left and right sections are held together with counter sunk-screws instead of the crimped projections according to the construction made of U.S. Pat. No. 2,077,763. Additionally the U-shaped guide assembly of the '763 patent is eliminated and a trigger guide assembly is contoured into the cast left and right sections of the pistol to make construction simpler and less expensive.

Abstract: An apparatus and a method for manufacturing cast parts by means of a lost wax process which is fully automated and unmanned. The wax tree coating processes, ranging from after a wax tree manufacturing step to immediately before a dewaxing step comprises a handling device for handling wax trees, a pair of slurry fluid dipping baths disposed with the handling device in between, a pair of sanding fluidized bed tanks disposed with the handling device in between, and a pair of conveyors for suspending and transferring the wax trees for not less than given drying time, wherein the handling device chucks the wax tree suspended and transferred by the conveyor at a given transfer position by means of a clamp unit of the handling device, moves the wax tree to the slurry fluid dipping bath and then to the sanding fluidized bed tank to coat the wax tree with a slurry fluid and sand, and returns the coated wax tree to the hanger conveyor again, with the sequence of operations automatically controlled by a controller.

Abstract: A method and an apparatus are provided which allows the safe and inexpensive extinguishing and cooling of flaming wax emanating from an investment casting flash fire dewaxing furnace. Investment mold structures are disposed within individual cups which direct flaming wax material downwardly through individual openings in the furnace floor. Flaming wax is then extinguished within an extinguishing chamber by a stream of non-aqueous inert gas. The process makes flash fire dewaxing of investment mold structures efficient and safe and provides for easy recycling and reuse of the wax because it is not contaminated with water or other contaminant materials.

Abstract: A new method for producing a composite ceramic mold for production of metal castings is disclosed. The composite mold is comprised of a backing layer and a facing layer. The backing layer is formed by pouring a mixture of a suitable refractory, a gelling agent, and a binder about an oversized pattern. After the backing layer hardens, it is fired and then baked. The facing layer is then formed integrally with the backing layer by pouring a mixture of comminuted highly refractory material, a gelling agent, and a binder between the oversized backing layer and a dimensionally-correct pattern. After the facing layer hardens, it is fired and then baked.