Abstract: The disclosure relates generally to core compositions and methods of molding and the articles so molded. More specifically, the disclosure relates to core compositions and methods for casting hollow titanium-containing articles, and the hollow titanium-containing articles so molded.

Abstract: A ceramic core includes sintered ceramic powder and a hole opening on a surface of the ceramic core and having an opening portion with a maximum size of 100 ?m or less. A manufacturing method for a ceramic core includes: preparing an injection molding composition by mixing ceramic powder and a binder; manufacturing a ceramic compact by performing the injection molding of the injection molding composition; and manufacturing a ceramic core by sintering the ceramic compact, wherein cumulative percentage of coarse powder with a particle diameter of more than 50 ?m included in the ceramic powder is 30% or less on an integrated volume particle size distribution curve of the ceramic powder.

Abstract: Cores that are inserted into the mold during the die casting of workpieces from metal in order to keep the cavities provided in the workpieces free during the filling of the molds with the melt have to meet demanding requirements with regard to the dimensional stability and suitability thereof for removal from the cavities. Therefore, salt-based cores which can be produced by molding and compressing a core material mixture are provided according to the invention, the core materials thereof being selected from at least one salt, at least one binder system comprising a combination of binder/binding agent and optionally auxiliary substances such as additives, fillers, wetting agents and catalysts, wherein the salt, the binder system and the optionally used auxiliary substances of the core material mixture are inorganic, and these core materials are soluble with water as the solvent.

Abstract: A core assembly for a turbine engine blade includes a generally radially extending trunk interconnected to multiple generally axially extending tabs. The tabs are interconnected by a generally radially extending ligament. Multiple generally axially extending protrusions are interconnected to the ligament opposite the trunk. A mold is configured to define an exterior surface of an airfoil. The core is arranged within the mold and is configured such that the tabs and the ligament break through at the exterior surface.

Abstract: A core for forming a cooling microcircuit has at least one row of metering/tripping features configured to form at least one row of protrusions in the cooling microcircuit, a plurality of teardrop features configured to form a plurality of fluid passageways in the cooling microcircuit, and a terminal edge. The plurality of teardrop features includes a central teardrop feature having a trailing edge which is spaced from the terminal edge and a first teardrop feature located on a first side of and spaced from the central teardrop feature. The first teardrop feature has a longitudinal axis and is non-symmetrical about the longitudinal axis. A process of using the core and a turbine engine component formed thereby are described.

Abstract: A hybrid ceramic/sand casting method of manufacturing a metal part. The method is especially suitable for manufacturing engine cylinder blocks or cylinder head, which have very small internal passages or other very small internal features. These parts are formed using a hybrid core having at least one ceramic section and at least one sand section, with the ceramic section being used to create the internal feature. A mold cavity is created for the part, and the hybrid core is positioned in the mold. Molten metal is introduced into the mold, and after the metal cools, the core is removed, thereby forming the part with the internal feature.

Abstract: A method of casting a component (42) having convoluted interior passageways (44). A desired three dimensional structure corresponding to a later-formed metal alloy component is formed by stacking a plurality of sheets (18, 20) of a fugitive material. The sheets contain void areas (22) corresponding to a desired interior passageway in the metal alloy component. A ceramic slurry material is cast into the three dimensional structure to form either a ceramic core (34) or a complete ceramic casting vessel (38). If just a ceramic core is formed, a wax pattern is formed around the ceramic core and an exterior ceramic shell (38) is formed around the wax pattern by a dipping process prior to the removal of the fugitive material and wax. An alloy component having the desired interior passageway is cast into the casting vessel after the fugitive material is removed.

Abstract: A ceramic casting core, including: a plurality of rows (162, 166, 168) of gaps (164), each gap (164) defining an airfoil shape; interstitial core material (172) that defines and separates adjacent gaps (164) in each row (162, 166, 168); and connecting core material (178) that connects adjacent rows (170, 174, 176) of interstitial core material (172). Ends of interstitial core material (172) in one row (170, 174, 176) align with ends of interstitial core material (172) in an adjacent row (170, 174, 176) to form a plurality of continuous and serpentine shaped structures each including interstitial core material (172) from at least two adjacent rows (170, 174, 176) and connecting core material (178).

Abstract: A core (10) for casting a hollow component of a turbomachine. The core includes a first portion (12) for providing a shape to the component and a second portion (14) located outside of the component. The second portion (14) comprises a plurality of indentations (16) for preventing a breakage of the core (10) at a region proximal to the first portion (14).

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 to have a joint-forming surface with a male and/or female joint feature and then forming at least one fugitive core insert in-situ adjacent and integrally connected and fused to the at least one preformed core insert at the joint-forming surface to form an interlocked, fused joint to form a composite core insert that includes features to form internal passage surfaces in the core when the composite core insert is removed. Another aspect involves preforming first and second fugitive core inserts to have respective joint-forming surfaces with respective snap-fittable joint features and assembling the first and second fugitive core inserts to form a composite core insert by snap fitting the snap-fittable joint features together to form an interlocked joint.

Abstract: The subject matter of the invention relates to sizing compositions as coating compositions for casting molds. The sizing composition is suitable for cores and molds, in particular those produced using water glass as a binder. The sizing composition contains certain salts.

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 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 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 system for producing cast components from molten metal. One form of the present invention includes a system for the precision pouring of molten metal within a casting mold.

Abstract: A casting core resulting from alkaline earth metal oxide particles having an average particle size of 0.8-4 mm being dispersed in a water-soluble alkali metal salt matrix. The casting core can be efficiently produced using a method of dispersing alkaline earth metal hydroxide particles having favorable disintegration properties and a particle size in the range of 1-5 mm in a molten water-soluble alkali metal salt, converting to alkaline earth metal oxide particles by means of dehydration, and casting in a mold, cooling, and hardening.

Abstract: A method for the high pressure die casting of an engine block assembly having at least one cast in place cylinder bore in the engine block and a closed head deck surface, and the resultant engine block are disclosed. This closed deck high pressure die cast engine block assembly will preferably have at least two cast in place cylinder bores in the engine block formed by using a composite core of salt core material supported by at least one cylinder bore to be cast in place. The cylinder bores have a lower outer surface preferably defining at least one surface area that interfaces with the engine block during casting such that the at least one cylinder is cast in place in the engine block. An engine block water jacket—as defined by the salt core portion of the composite core—will preferably provide an open passage between each cylinder bore such that water may flow around and entire outer circumference of the upper outer surface of the cylinder bores.

Abstract: A method is provided for repairing defects in a ceramic core adapted for use in a casting process. The ceramic core is formed from a slurry comprising at least one refractory powder material suspended in a liquid vehicle. The method includes forming a repair mixture comprising a liquid diluent and the at least one refractory powder material suspended in the liquid vehicle of the slurry. The repair mixture is applied to a region of the ceramic core that includes at least one defect and then the ceramic core is fired to burn off the liquid vehicle in the repair mixture and form a ceramic composition that closes the defect.

Abstract: A hollow turbine engine component with complex internal features can include a first region and a second, high resolution region. The first region can be defined by a first ceramic core piece formed by any conventional process, such as by injection molding or transfer molding. The second region can be defined by a second ceramic core piece formed separately by a method effective to produce high resolution features, such as tomo lithographic molding. The first core piece and the second core piece can be joined by interlocking engagement that once subjected to an intermediate thermal heat treatment process thermally deform to form a three dimensional interlocking joint between the first and second core pieces by allowing thermal creep to irreversibly interlock the first and second core pieces together such that the joint becomes physically locked together providing joint stability through thermal processing.

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 gravity casting mold including a first mold, a second mold and an exhaust runner mold, which are combined with each other and form a turbine housing cavity having a twin scroll part, a first riser, a sprue, a runner, a second riser, an exhaust manifold cavity, third risers and gates. A heating sleeve is provided in the first riser so as to prevent shrinkage of the molten metal in the twin scroll part. The heating sleeve is closed in an upper end, with a gas ejection hole formed through the upper end of the heating sleeve. A sprue cup is provided in the sprue so as to maintain the temperature of the molten metal in the sprue. The gravity casting mold further includes a twin scroll mold, a main gate core, an exhaust runner core, a twin scroll part core and a bypass part core, and a sub-gate core.

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

Abstract: An investment casting core includes a mullite-containing core body. The body can be made by providing a mullite-containing powder, forming the powder into a green body, and sintering the green body to form the mullite-containing core body.

Abstract: An airfoil for a turbine engine includes a structure having a cooling passage that has a generally radially extending cooling passageway arranged interiorly relative to an exterior surface of the structure. The cooling passageway includes multiple cooling slots extending there from toward the exterior surface and interconnected by a radially extending trench. The trench breaks the exterior surface, and the exterior surface provides the lateral walls of the trench. The airfoil is manufactured by providing a core having multiple generally axially extending tabs and a generally radially extending ligament interconnecting the tabs. The structure is formed about the core to provide the airfoil with its exterior surface. The ligament breaks the exterior surface to form the radially extending trench in the exterior surface of the structure.

Abstract: A method of fabricating a decomposition conduit with an in-line static mixer, the method including molding a decomposition conduit housing around a sand core by inserting molding material into a cavity between a decomposition conduit housing mold and the sand core, where the sand core includes a static mixer and, where the act of molding the decomposition conduit housing is operative to mount the static mixer to the molded decomposition conduit housing.

Abstract: An apparatus and method for molding a freight car yoke with a one piece core is disclosed herein. An exemplary one piece core may be used with a core mold upper half and a core mold lower half mated at a common split line to define a mold cavity which replicates the molded exterior features of a freight car yoke. The one piece core may replicate all of the molded internal features of a freight car yoke. An apparatus may use a pair of one piece cores to produce a pair of freight car yokes. An exemplary method can utilize the apparatus to produce a pair of freight car yokes through a single pour, using a pair of one piece cores. In an exemplary embodiment the one piece cores are constructed from a cold box with phenolic urethane treated molding sand.

Abstract: A core or foundry sand that can be used for the production of cores and casting molds for the casting of molten metals includes a basic molding material, a layer of an adhesive agent coating the basic molding material, and a layer of water glass lying over the adhesive agent layer. The core or foundry sand has a water content in the range of ? approximately 0.25% by weight to approximately 0.9% by weight in relation to the overall weight of the core or foundry sand.

Abstract: This invention teaches an improved apparatus and method to make metal alloy castings, such as freight car yokes. One embodiment of the invention comprises a core mold assembly unit, wherein the mold unit is filled with molten metal. The core mold assembly units may be further formed of the same material, such as phenolic urethane impregnated sand, which is used to accurately replicate the desired shape of a final desired product.

Abstract: A method of manufacturing a metal blading sector for low-pressure guide vanes of a turbomachine of which at least one blade includes an internal cavity configured to accept or communicate with a gas detection probe and at least one hole formed in the wall constituting a passage for gas from a low-pressure zone of the turbomachine toward the cavity and the probe through the fitting, into a casting mold, of a core corresponding to the cavity and the casting of a molten metal in the cavity of the casting mold. The core includes, for each hole for communication with the cavity, a protrusion penetrating the internal surface of the mold and constituting the only element holding the core in position in the casting mold.

Abstract: A polyisocyanate component for a moulding material binding agent system is described containing at feast one sulfonic acid in a solution of at least one polyisocyanate, containing at least two NCO-groups in the molecule.

Abstract: A melt is made by heating a salt mixture containing a salt of sodium. The melt is set at a temperature higher than the liquidus temperature of the salt mixture, and poured into a mold for expendable core molding. The temperature when the melt is completely poured into the mold is set within a range not exceeding the liquidus temperature of the salt mixture by 30° C. An expendable salt core for casting is molded by solidifying the melt inside the mold. This makes it possible to more stably obtain the strength of a water-soluble expendable salt core for casting made of a salt cast product obtained by melting and molding salts of sodium and the like.

Abstract: Heat flow and mechanical strength of an engine component are improved by an organic-like casting core. Hardened granules are formed of a core material having a three-dimensional solid shape. A secondary binder is applied to the hardened granules. A multiplicity of the granules are agglomerated in a master mold in a shape of a water jacket of the engine component, and the secondary binder is hardened to form an organic-like core having a continuous web structure. A plurality of other cores are formed in respective master molds to define respective surfaces of the engine component. The organic-like core is assembled with the other cores to form a casting mold. The engine component is cast by flowing molten metal into the casting mold, thereby forming a continuous parent metal bridging the water jacket having a predetermined porosity. The core material is removed from the engine component after casting.

Abstract: The invention relates to a method for producing a cylinder (10, 110) for a two-stroke engine, comprising the following steps: producing a casting core (30, 130), wherein a central core slide (31, 131) for the cylinder chamber (11, 111) and at least one salt core (33, 133) for an overflow channel (18, 19; 118, 119) are produced and the at least one salt core (33, 133) is connected to the central core slide (31, 131), inserting the casting core (30, 130) into a casting mold, casting the cylinder (10, 110) in a die-casting process, removing the central core slide (31, 131) from the cylinder (10, 110), wherein the at least one salt core (33, 133) is separated from the central core slide (31, 131), and flushing the at least one salt core (33, 133) out of the cylinder (10, 110). The invention further relates to a casting core (30, 130) for such a method.

Abstract: An exemplary method for forming a sand core includes forming a core insert; forming a sand core precursor around the core insert; and creating at least one passage within the sand core precursor by removing or otherwise transforming a portion of the core insert, wherein the at least one passage includes at least one exit point. The sand core may then be utilized in a casting mold assembly to form a cast part.

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 to have a joint-forming surface with a male and/or female joint feature and then forming at least one fugitive core insert in-situ adjacent and integrally connected and fused to the at least one preformed core insert at the joint-forming surface to form an interlocked, fused joint to form a composite core insert that includes features to form internal passage surfaces in the core when the composite core insert is removed. Another aspect involves preforming first and second fugitive core inserts to have respective joint-forming surfaces with respective snap-fittable joint features and assembling the first and second fugitive core inserts to form a composite core insert by snap fitting the snap-fittable joint features together to form an interlocked joint.

Abstract: A core assembly for casting a railcar coupler knuckle includes a first core and a second core. The first core includes a lug. A slot is defined in the second core. First and second positive stop surfaces are provided. The invention reduces core shifting during casting and therefore improves the strength and fatigue life of a coupler knuckle.

Abstract: A composite core die includes a reusable core die; and a disposable core die. The disposable core die is in physical communication with the reusable core die and surfaces of communication between the disposable core die and the reusable core die serve as barriers to prevent the leakage of a slurry that is disposed in the composite core die.

Abstract: A method for deburring a ceramic foundry core obtained by injecting a ceramic paste, the paste including a binder having a predetermined glass transition temperature, into a mold and having at least one surface portion with a surplus of material forming a burr to be eliminated. The method includes the following stages: a) disposing and attaching the molded, unfired foundry core onto a mounting; b) placing a milling tool, having an elongated shape with a helically cut edge, onto a tool holder; c) causing the tool to rotate around its axis and touching the milling tool to the surface portion to be deburred; and d) freezing the surface portion to be deburred such that the foundry core is maintained at a temperature lower than a glass transition temperature during the deburring operation.

Abstract: Heat flow and mechanical strength of an engine component are improved by an organic-like casting core. Hardened granules are formed of a core material having a three-dimensional solid shape. A secondary binder is applied to the hardened granules. A multiplicity of the granules are agglomerated in a master mold in a shape of a water jacket of the engine component, and the secondary binder is hardened to form an organic-like core having a continuous web structure. A plurality of other cores are formed in respective master molds to define respective surfaces of the engine component. The organic-like core is assembled with the other cores to form a casting mold. The engine component is cast by flowing molten metal into the casting mold, thereby forming a continuous parent metal bridging the water jacket having a predetermined porosity. The core material is removed from the engine component after casting.

Abstract: An internal gear manufacturing method capable of manufacturing time reduction and easy core removal, and a metallic glass internal gear manufactured thereby. A carbon core formed into a shape of an external gear is arranged in a thin, long tubular mold of a length equal thereto with a space extending longitudinally therealong. A molten metal material is pressure-injected under a temperature higher than a melting point thereof into the space between the mold and the core. The molten metal material is resolidified by rapid cooling at or above a critical cooling rate thereof together with the mold and the core. After resolidification of the molten metal material, the core is removed by pulverization or dissolution. Along internal gear formed of the resolidified metal material is cut into a plurality of segments of a prescribed length.

Abstract: A composite core die includes a reusable core die and a disposable core die; where the disposable core die is in physical communication with the reusable core die; and further where surfaces of communication between the disposable core die and the reusable core die serve as barriers to prevent the leakage of a slurry that is disposed in the composite core die.

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: 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: A method for applying a refractory coating to a sand core, to be used for a metal casting, in a dry state, without the use of a liquid carrier. The coating may be applied by pressing the coating into a mixture of refractory material and impacting media fluidized in a vibratory bed such that the core floats in the mixture, and then rotating the core to coat the surfaces that will be in contact with the molten metal in the casting process.

Abstract: The present invention provides a structure for producing cast articles containing one or more inorganic particles selected from amorphous and artificial graphites, an inorganic fiber and a thermosetting resin and having a gas permeability of 1 to 500.

Abstract: It is a technical common knowledge that a chaplet used in casting of a hollow casting is fusion-bonded with the melt and is incorporated into the casting. However, the adhesion between the chaplet and the casting body is not necessarily satisfactory, thereby incurring the strength reduction of a thin-wall hollow casting. A core for a thin-wall hollow casting according to the present invention is provided with a chaplet mounted thereon. The chaplet has arcuate portion 2 with a gap 5 and a plurality of projections 4 from an outer peripheral of the arcuate portion and is in contact with an inner wall 7 of a mold. The entire arcuate portion of the chaplet is included in a groove 6 formed around an outer peripheral portion of the core body. Only the projections 4 of the chaplet protrude from the core body, when the chaplet is inserted in the groove.

Abstract: A core for creating an airfoil has a ceramic material that forms a body. The body has an outer dimension, a slot extending through the outer dimension and into the body for receiving an insert, the slot disposed at an angle to the outer dimension, and a trip strip having a first portion disposed in the outer dimension. The first portion is in register with the slot wherein a constant dimension such as minimum thickness is maintained between the trip strip and the slot along a length of the slot and wherein said first portion tapers towards said outer dimension.

Abstract: Diecasting tool for the production of a cylinder crankcase (2), comprising a salt core (4) and at least one cylinder sleeve (6), wherein the cylinder sleeve (6) comprises an upper end (8) on the cylinder head side, and a lower end (10) on the crankshaft side, and the cylinder sleeve (6) is supported on at least one center sleeve that is disposed on the diecasting tool, and the salt core (4) at least partially surrounds the cylinder sleeve (6) in the manner of a cladding, wherein the salt core (4) comprises a crown (12) that at least partially bears on one of the ends (8, 10) of the cylinder sleeve (6), and the core (4) comprising openings (14) that extend vertically beneath the end (8) of the cylinder sleeve (6) on the cylinder head side.

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: The present disclosure is directed to a refractory metal core for use in forming varying thickness microcircuits in turbine engine components, a process for forming the refractory metal core, and a process for forming the turbine engine components. The refractory metal core is used in the casting of a turbine engine component. The core is formed by a sheet of refractory metal material having a curved trailing edge portion integrally formed with a leading edge portion.