Abstract: According to the prior art, through-holes in components are often introduced after the production (casting) of the component. This entails additional outlay in terms of time and equipment. The time required can be considerably shortened if a casting mold is designed in such a way that the through-hole is at least in part formed by corresponding projections being formed on the inner wall and/or the outer wall of the casting mold.

Abstract: A core for casting a metal part having a body with solid portions spaced apart by hollow portions. The body includes at least one support element extending between adjacent solid portions. The support element provides stiffness and strength for the casting core during the casting process. The support element has an optimized shape to prevent the core from fracturing during the casting process and to minimize operating stress in the metal part around the area formed by the support element.

Abstract: A substrate is coated by applying an essentially pure aluminum first layer to a surface of the substrate. At least a first portion of the first layer is oxidized so as to provide a protective coating of desired properties. The substrate may be a refractory metal-based investment casting core.

Abstract: A substrate is coated by applying a first layer atop the substrate and comprising, in major weight part, a non-refractory first metal. A second layer is applied atop the first layer and comprises, in major weight part, a carbide and/or nitride of a second metal. A third layer is applied atop the second layer and comprises, in major weight part, a ceramic. The substrate may be a refractory metal-based investment casting core.

Abstract: In accordance with the present invention, a casting system is provided which broadly comprises a core and a wax die spaced from said core, a refractory metal core having a first end seated within a slot in the core and a second end contacting the wax die for positioning the core relative to the wax die, and the refractory metal core having at least one of a mechanism for providing spring loading when closed in the wax die and a mechanism for mechanically locking the wax die to the core.

Abstract: An investment casting pattern is formed by installing a first core to a first element of a molding die to leave a first portion of the first core protruding from the first element. After the installing, the first element is assembled with a feed core and a second element of the molding die so that the first portion contacts the feed core and is flexed. A material is molded at least partially over the first core and feed core.

Abstract: The present invention relates to A method and apparatus for making a sand core (112) utilizing purge air through a core box (100 and 100?) to harden the binder in the sand core (112) proximate the ejection pins (106 and 106?). The sand core (112) may be removed from the core box (100 and 100?) prior to drying the binder completely thereby resulting in an improved production rate of the sand core (112).

Abstract: An intake or exhaust port molding core of a cylinder head includes a plurality of protruders on the core to form a plurality of depressed grooves in the intake or exhaust port during casting of the cylinder head. The disposition and orientation of the intake or exhaust port formed inside the cylinder head can then be easily and precisely measured via the depressed grooves.

Abstract: A process for the production of a braking band having ventilation ducts comprises the steps of a) moulding a core of metallic material, b) inserting the core in a mould, in a central position, c) filling the mould with at least two layers of material which are to form the braking band, in a manner such that the core is “sandwiched” between the at least two layers, d) performing a first heating of the mould to a temperature such as to bring about hardening of the at least two layers until the at least two layers adopt a three-dimensional structure, e) subjecting the semi-finished product produced in step d) to a second heating to a temperature such as to bring about fusion of the metallic material of the core, and f) collecting the molten core.

Abstract: A composite core for an investment casting process, the core including both a ceramic portion and a refractory metal portion, with the refractory metal portion being so disposed as to perform the function of a plurality of such refractory metal elements. In particular, a refractory metal element attached to a trailing edge of a ceramic element extends beyond the plane of a tip end of the ceramic element so as to replace the refractory metal element otherwise extending from the ceramic tip edge. The refractory metal element also extends beyond the space to be occupied by the wax casting, both in the direction of the tip end and the trailing edge such that improved placement and securing of the core is facilitated during the casting process. A further embodiment uses a single refractory metal element that extends into both the airfoil portion and an orthogonal extending platform portion thereof.

Abstract: A ceramic core for use in casting an article such as for example an airfoil, wherein the ceramic core has a pocket located at or near a region of the core that is otherwise associated with occurrence of a localized casting defect in the cast article. A covering is disposed on the core to cover the pocket and provide core outer surface features.

Abstract: The present application relates to a method of producing a metal article having an internal passage coated with a ceramic coating. The method comprises: preparing a core for defining the internal passage; applying the ceramic coating on the core; assembling the core with the ceramic coating applied thereon into a mold; casting metal into the mold at a pour temperature lower than the melting temperature of the ceramic coating; and removing the core. The ceramic coating may be applied by plasma spraying or slurry deposition.

Abstract: A pin used in investment casting, or the lost wax process, to support the ceramic core of a mold includes a core formed of a metal which provides suitable strength to maintain the position of the ceramic core during pouring of molten metal into the mold but which is susceptible to oxidation during firing of the mold. The pin core is encased with an outer coating formed of a metal which resists oxidation during firing of the mold and resists chemical interaction during processing of the cast part. An intermediate coating is preferably disposed between the core and outer coating and is likewise formed of a metal which resists oxidation during firing of the mold and resists chemical interaction during processing of the cast part. The invention also includes an investment casting mold using a plurality of these pins and methods of making the pin and the mold.

Abstract: An airfoil, a method of manufacturing an airfoil, and a system for cooling an airfoil is provided. The cooling system can be used with an airfoil located in the first stages of a combustion turbine within a combined cycle power generation plant and involves flowing closed loop steam through a pin array set within an airfoil. The airfoil can comprise a cavity having a cooling chamber bounded by an interior wall and an exterior wall so that steam can enter the cavity, pass through the pin array, and then return to the cavity to thereby cool the airfoil. The method of manufacturing an airfoil can include a type of lost wax investment casting process in which a pin array is cast into an airfoil to form a cooling chamber.

Abstract: A golf club head of the present invention. A cast head body 31 is constituted by a hollow outer shell. Said hollow outer shell define a top portion 35, a sole portion 37, a heel wall 45, a toe portion 39 and a face opening portion 33. A shaft securing portion 43 is formed adjacent to the heel wall and extended from the top portion to the sole portion. And a first hollow portion 47 is formed between the shaft securing portion and the heel wall of the head body.

Abstract: A disintegrative member, such as a salt core, is provided with a vent opening extending through its thickness from an outer surface to an inner surface in order to allow gases to pass radially inwardly through the body of the salt core and away from a region proximate the salt core's outer surface. The escape of these gases through the vent opening decreases the likelihood that porosity will be formed as a result of those gases being trapped in a region proximate the outer surface of the salt core because the molten metal solidifies more slowly in this area because of the thermal insulative qualities of the disintegrative member.

Abstract: An apparatus for casting an ingot includes a molten metal reservoir (51) positioned at an upper portion, a casting chamber (5) positioned at a lower portion and a partition wall (3) between the reservoir and the chamber, a spruce (7) formed in the partition wall, an opening/closing plug (8) for opening and closing the sprue and control means for controlling an opening and closing operation of the plug. The casing chamber is defined in a mold (1) that includes a lower mold member (4), a side mold member (2) and the partition wall (3) that constitutes an upper mold member. At least one of the lower mold member, side mold member and upper mold member includes a plurality of divided sections (21,22) in accordance with a shape of a cast ingot C.

Abstract: A method for producing a damped part where a sand core is formed with at least one dampening structure with the sand core. The sand core with the at least one dampening structure therein is located in a mold. A part is cast from the mold and the sand core. The sand core is removed from the cast part leaving the at least one dampening structure in contact with the part.

Abstract: A sacrificial core for forming an interior space of a part includes a ceramic core element and a first core element including a refractory metal element. The ceramic core element may be molded over the first core element or molded with assembly features permitting assembly with the first core element.

Abstract: A method for casting an airfoil for a turbine engine is provided. The method includes forming a casting core to define a hollow portion in the airfoil and forming a print out region at one end of the casting core. The method also includes coupling the casting core to the print out region with at least one frusto-conical member to facilitate structurally supporting the casting core.

Abstract: A casting system for forming a gas turbine engine component is provided. The casting system, in a first embodiment, comprises a shaped refractory metal sheet having a plurality of features for forming a plurality of film cooling passages, which features are formed from refractory metal material bent out of the sheet. The casting system for forming a gas turbine engine component in a second embodiment comprises a metal wall having an airfoil shape and a refractory metal core adjacent the metal wall and having a shape corresponding to the shape of the metal wall.

Abstract: A cylinder block has a number of cylinder bores and a water jacket at least partially surrounding the bores. When casting a cylinder block the water jacket is formed by a slender wall of a sand core. To enable the wall to be removed from the core box the wall must taper over its entire height. Prior art water jackets therefore taper from a minimum sand core wall width at the base to a large width at the top. The cylinder block of the invention has a water jacket which, when viewed in transverse section, is wider in an intermediate portion than at either its top or base. In providing a water jacket which is narrower at the top, there is more room for the addition of machined features on the top deck. Furthermore, a water jacket which is narrower at the base can have a greater depth than conventional water jackets.

Abstract: To prevent movement of a ceramic core in a ceramic shell for the investment casting of a turbine blade, the free end of the core has one or more pins embedded therein so that the pins project into both the core and the ceramic shell which is applied over a wax layer. After removal of the wax and firing of the shell, molten metal is cast in the space left by the wax between the core and the shell. After hardening of the metal, the outwardly projecting part of the pins are removed during the machining of the surfaces of the turbine blade blank.

Abstract: There is provided a ceramic fiber casting core used in making cast metal parts comprised of a ceramic fiber structure. The casting core may further comprise a support tube in structural supporting relation to the ceramic fiber structure. There is also provided a method to manufacture the ceramic fiber casting core that comprises mixing ceramic fibers and a binder in a mix tank. Pouring the resultant mixed slurry into a vacuum forming tank. Inserting a perforated mandrel into the vacuum forming tank. Forming a vacuum inside the mandrel resulting in vacuum depositing of the ceramic fiber on the mandrel. Removing the ceramic fiber casting core and mandrel from the vacuum forming tank. Removing the mandrel, and then drying and curing the ceramic fiber structure. When necessary, locating a support member in structural supporting relation to the ceramic fiber structure. Machining the unfinished casting core to a desired outside dimensions.

Abstract: An apparatus and method for casting metallic components is disclosed. The apparatus has a vertical parting line and a gate configuration which reduces defects within the cast components.

Abstract: The invention provides a method with which high-quality complex-shaped castings can be manufactured and with which, after the end of the casting process, the casting mould parts can be easily removed out of or from the casting without any risk.

Abstract: A water-dispersible casting mould, particularly a core, for the manufacture of castings is proposed. The mould contains a water-insoluble, particulate material, such as moulding sand, a binder, which has a first binder component based on a condensed phosphate, and optionally a flux. In order to ensure an increased flexural strength and abrasion resistance, there is a second binder component based on polyamines. It is also possible to provide a flux based on alkali metal carbonate, which gives the mould an increased thermal stability. The invention also relates to a method for the manufacture of such a mould, in that the aforementioned components are mixed, accompanied by the addition of water, the mixture is moulded and at least part of the added free water is removed.

Abstract: A method for treating an unfired, molded ceramic core comprises placing an unfired (green) ceramic core having a thermosetting and/or thermoplastic binder on at least one setter, placing the setter and the green ceramic core thereon on a conveyor, conveying the setter and the green core through the heating oven to heat the setter and the green ceramic core to an elevated superambient temperature at or above a softening temperature of the binder present in the green core. Heating of the green ceramic core in this manner conforms the core to a surface of the setter to reduce distortion of the core and improve yields of cores that are within preselected dimensional tolerances.

Abstract: The invention relates to a method and tools for producing a braking band (2) of a disk-brake disk (1) by casting, in which the disk comprises at least two plates (3, 3′) connected to one another by connecting elements (4) forming an internal air-duct (7) for the cooling of the braking band (2). With the method and the tools, a disk is produced in which at least one of the plates (3, 3′) has, in its surface (8, 8′) defining the air-ducts (7), at least one groove (10, 10′) having a cross-section which becomes wider towards the air-duct.

Abstract: A casted workpiece includes a wall including passages in the form of a three-dimensional grid. A casted three-dimensional grid coating of the passages is one piece with the remainder of the workpiece.

Abstract: Disclosed is a method for manufacturing a disintegrative core for use in high pressure casting. The disintegrative core can be applied where a light metal such as an aluminum alloy or magnesium alloy is subjected to high pressure casting, such as die casting or squeeze casting and is manufactured from a water-soluble salt which is high in latent heat and ranges, in melting point, from 280 to 520° C. and, in heat transfer coefficient (&kgr;), from 9.8×10−2 to 1.2×10 W/m·° C. The water-soluble salt, alone or in combination with a fine hard powder, is melted and solidified in a core mold. Alternatively, the melt is processed into a fine powder which is then molded in a core mold. The method can be applied for the manufacture of complex shapes of cores. Also, disclosed is a method for extracting such a core from a high pressure molded product.

Abstract: A method for casting an airfoil for a turbine engine is provided. The method includes forming a casting core to define a hollow portion in the airfoil and forming a print out region at one end of the casting core. The method also includes coupling the casting core to the print out region with at least one frusto-conical member to facilitate structurally supporting the casting core.

Abstract: In a method of producing a turbine blade in hollow section, an especially low defect or scrap rate is to be ensured. To this end, a first core element is connected via a number of approximately cylindrical spacers to a further core element and/or to a casting mold, the cavities left in the casting mold by the core elements being filled by blade material, and the openings remaining in the turbine blade after the removal of the core elements and the spacers and produced by the spacers being closed by stopper elements.

Abstract: A core for a shell die used in casting a turbine bucket includes an elongated body shaped to create internal cooling passages in the bucket, the elongated body formed with at least one core support pin extending transversely of the elongated body and adapted to fix the core inside the shell die, at least one core support pin having an elliptical shape in cross-section. The invention also relates to a cast turbine bucket with at least one exit hole formed therein during casting. The exit hole and a plug for closing the hole are elliptical in cross-section.

Abstract: The invention relates to a method for producing a cast part of a thermal turbo-machine by way of a known casting process. Between a model mold and a ceramic insert, projections are located on the ceramic insert, whereby the projections have an angle (&agr;, &bgr;) between the center line and the outer edge of the projections of less than 30°, and whereby the projections are used both for the fixation of the insert during the casting process and for the reduction of the notch factor inside the recesses created in the cast part.

Abstract: A core rod is utilized in the process of forming a core in a metal casting. The core rod has a length and opposite ends The core rod is generally round in cross-section along at least a portion of the length of the core rod proximate at least one of the ends configured for use in forming the core of the metal casting. The core rod is made from a precipitation-hardenable alloy including about 40.0 to 75.0 wt. % Ni, about 0.0 to 25.0 wt. % Co, about 10.0 to 25.0 wt. % Cr, and about 0.0 to 20.0 wt. % Fe. A method for forming a core within a metal casting includes the steps of providing a precipitation-hardenable alloy core rod having a length and opposite ends; packing sand around at least one end of the core rod to form a sand core with core rod; placing the sand core with core rod into a mold; pouring molten metal into the mold and around the sand core with core rod; and producing a metal casting having a core and a uniform sidewall thickness in a range of ±0.060 inches.

Abstract: Concepts for fabricating improved cores for investment casting are described. The cores are composite which include refractory metal elements and ceramic elements. The refractory metal elements are provided to enhance the mechanical properties of the core and/or to permit the fabrication of cores having shapes and geometries that could not otherwise be achieved. In one embodiment, the entire core may be made of refractory metal components. The cores may be used to investment cast gas turbine superalloy components.

Abstract: A method for casting a workpiece comprising the steps of applying a protective coating to a base core the base core comprising, a metal strip comprising a generally planar expanse, a plurality of tabs arranged in a pattern upon the metal strip each of the tabs comprising a base end, a terminus end, and a tab shaft extending from the base end to the terminus end wherein each of the tabs is angularly displaceable about each the base end of the tabs, injecting a molding substance about the tabs of the base core, encapsulating the base core in a shell, removing the molding substance, casting the base core, and removing the base core.

Abstract: The present invention relates to a method and apparatus for making a sand mold (112) utilizing reverse purge air through a core box (100 and 100′) to harden the binder in the sand mold (112) proximate the ejection pins (106 and 106′). The sand mold (112) may be removed from the core box (100 and 100′) prior to drying the binder completely.

Abstract: The number of cores used in casting bolsters and sideframes is reduced. End cores and a center core are placed in a mold with cope and drag portions. Each core includes integrally-formed portions for defining portions of the interior surfaces of the bolster or sideframes. The integrally-formed portions may include a portion for defining the side window of the sideframe formed integrally with other portions, and may include a pedestal portion formed integrally with other portions. The integrally-formed portions may contact both the cope and drag portions of the mold. The end cores may include integrally formed core prints for supporting the core in the mold. The integrally-formed portions of the center core include connections that are formed integrally with the other portions. Molten metal is introduced into the mold to cast the bolster or sideframe.

Abstract: The present invention provides a method of casting a sideframe including the steps of dividing the sideframe into design zones, and providing a core module for forming internal surfaces of the sideframe casting in the design zones. The design zones include a right outer leg design zone, a left outer leg design zone, a right tension member design zone, a left tension member design zone, and a bolster opening design zone. The present invention also includes the step of varying at least one core module to correspond with varying sideframe casting geometry in at least one design zone. The core modules include a right outer leg core module, a left outer leg core module, a right tension member core module, a left tension member core module, a right column wall core module, a left column wall core module, and a bolster opening bottom core module. The core modules define internal surfaces of the sideframe casting in their respective design zones.

Abstract: A method for casting a workpiece comprising the steps of applying a protective coating to a base core the base core comprising, a metal strip comprising a generally planar expanse, a plurality of tabs arranged in a pattern upon the metal strip each of the tabs comprising a base end, a terminus end, and a tab shaft extending from the base end to the terminus end wherein each of the tabs is angularly displaceable about each the base end of the tabs, injecting a molding substance about the tabs of the base core, encapsulating the base core in a shell, removing the molding substance, casting the base core, and removing the base core.

Abstract: Concepts for fabricating improved cores for investment casting are described. The cores are composite which include refractory metal elements and ceramic elements. The refractory metal elements are provided to enhance the mechanical properties of the core and/or to permit the fabrication of cores having shapes and geometries that could not otherwise be achieved. In one embodiment, the entire core may be made of refractory metal components. The cores may be used to investment cast gas turbine superalloy components.

Abstract: Method making a multi-wall ceramic core for use in casting airfoils, such as turbine blades and vanes, wherein a fugitive pattern is formed having multiple thin wall pattern elements providing internal wall-forming spaces of a final core, the pattern is placed in a core molding die cavity having a desired core configuration, a fluid ceramic material is introduced into the die cavity about the pattern and between the pattern elements to form a ceramic core, and the core is removed from the die cavity. The fugitive pattern is selectively removed from the core to provide a multi-wall green core. The green core then is fired to develop core strength for casting and used to form an investment casting mold for casting an airfoil.

Abstract: The number of cores used in casting sideframes is reduced. A pair of end cores and a center core are placed in a mold with cope and drag portions. Each core includes integrally-formed portions for defining portions of the interior surfaces of the sideframes. The integrally-formed portions may include a portion for defining the side window of the sideframe formed integrally with other portions, and may include a pedestal portion formed integrally with other portions. The integrally-formed portions may contact both the cope and drag portions of the mold. The end cores may include integrally formed core prints for supporting the core in the mold. The integrally-formed portions of the center core include connections that are formed integrally with the other portions. Molten metal is introduced into the mold to cast the sideframe.

Abstract: An aircraft door has an inner framework integrally connected to an outer skin by simultaneously casting the framework and the skin in a mold that holds a single core for each frame element in the form of a rib in a freight door or a beam in a passenger door. The ribs extend circumferentially relative to a longitudinal central axis of the aircraft. The beams extend in parallel to the central aircraft axis. The single core is selected from at least one core type and four core types at the most. The frame elements in the form of ribs or beams have open arches for a considerable weight reduction.

Abstract: An engine block mold package includes a barrel crankcase core having a plurality of barrels on each of which a respective cylinder bore liner is disposed. Each cylinder bore liner includes an inside diameter that is tapered along at least a portion of its length to match a draft angle present on the barrels to permit removal of the barrel crankcase core from a core box in which it is formed.

Abstract: An airfoil for a turbine nozzle assembly of a gas turbine engine includes an outer side wall, an inner side wall, a leading edge extending from the outer side wall to the inner side wall, a trailing edge extending from the outer side wall to the inner side wall, a concave surface extending from the leading edge to the trailing edge on a pressure side of the airfoil, a convex surface extending from the leading edge to the trailing edge on a suction side of the airfoil, an outer cooling slot, an inner cooling slot, and at least one middle cooling slot formed in the concave side of the airfoil adjacent the trailing edge.

Abstract: The molding sand comprises hollow microspheres of aluminum silicate, preferably with an aluminum content between 15 and 45% by weight, a wall thickness between 3 and 10% of the particle diameter and a particle size between 10 and 350 &mgr;m. These sands are useful to manufacture low density cores with good “veining” and penetration characteristics, moreover maintaining the mechanical properties of the core obtained. These cores are useful in the manufacture of iron casting.

Abstract: The number of cores used in casting bolsters and sideframes is reduced. End cores and a center core are placed in a mold with cope and drag portions. Each core includes integrally-formed portions for defining portions of the interior surfaces of the bolster or sideframes. The integrally-formed portions may include a portion for defining the side window of the sideframe formed integrally with other portions, and may include a pedestal portion formed integrally with other portions. The integrally-formed portions may contact both the cope and drag portions of the mold. The end cores may include integrally formed core prints for supporting the core in the mold. The integrally-formed portions of the center core include connections that are formed integrally with the other portions. Molten metal is introduced into the mold to cast the bolster or sideframe.