Abstract: A method for producing a hollow metal part by casting, wherein a destructible core (20) is provided including a body (22) made of aggregate, and a shell (40) which surrounds the body and adheres thereto; the core (20) is positioned inside a mold (50); metal is melted and the liquid metal is injected, generally under pressure, into the mold (50), surrounding the core (20) embodying an interior space of the part; after solidification of the part, the body is disaggregated and it is removed through removal openings provided in the shell and the part; and the shell is destroyed and removed through removal openings provided in the part.

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

Abstract: 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 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 main body core box assembly for creating coupler head cores which are attachable to various shank cores includes a main body core box including two halves, each half including a pattern configured to form the outer walls of a first head core having a first shank core. A plug is insertable into an end of respective patterns to form a second, alternative head core having a first half of a connection joint attachable to a second shank core that includes a second half of the connection joint, the second shank core being different than the first shank core. The first half of the connection joint may be a male connector, where the plug includes a recess having an angled surface to create a notch on the male connector. The second half of the connection joint may be a female connector with a raised surface corresponding to the notch.

Abstract: A mold for manufacturing a composite drive shaft, most of which, except for opposite ends functioning as power transmission parts, has a tubular shape with a circular cross-section similar to that of a general shaft, and the shape of each end of which is changed so as to realize easy removal of the drive shaft from the mold after molding. Further, the present invention provides a composite drive shaft, which is manufactured using the mold and is configured such that, when a connection joint (metal yoke) is assembled with each end of the drive shaft, the drive shaft can be rotated in an integrated state realized by the connection joints. Thus, the composite drive shaft of the present invention can directly transmit power, instead of a mechanical fastening jointing technique or an adhesive bonding jointing technique, thus efficiently transmitting high torque.

Abstract: A process for casting a turbine engine component is provided. The process comprises the steps of placing a refractory core assembly comprising two intersecting plates in a die, encapsulating the refractory core assembly in a wax pattern having the form of the turbine engine component, forming a ceramic shell mold about the wax pattern, removing the wax pattern, and pouring molten material into the ceramic shell mold to form the turbine engine component.

Abstract: A mold and a die-cast manufacturing method for the die-cast product, in which a main frame which is contiguously formed with a head pipe constitutes a portion of a hollow light-weight-metal-made vehicle-body frame. The mold includes a core for forming an inner space of the hollow vehicle-body frame. The core includes a core body and a plurality of splints mounted on the core body, the splints having approximately elliptical cross-sectional shapes. The long axes direction of ellipses of the splints are set parallel to a mold split surface of the mold. As a result, measurement of the positional accuracy of the splints is facilitated, a clearance between the splint and the mold can decrease by increasing the dimensional accuracy of splint mounting portions of the mold based on sizes of the splints, and the frame can be manufactured with high dimensional accuracy.

Abstract: A core for use in casting a gas turbine bucket includes a solid, curved upper body portion and a pair of co-planar legs extending downwardly from the solid, curved upper body portions. The pair of legs are separated by an elongated open slot extending from a lower end of the core upwardly more than half a height dimension of the core, into the upper body portion. A pair of axially aligned pegs project in axially opposite directions from opposite sides of the solid, curved upper body portion, perpendicular to and above the elongated slot but spaced from an upper edge of the solid, curved upper body portion. The pair of pegs lie substantially in a plane containing the co-planar legs, and in a radial direction, the pegs are closer to the elongated slot than to the upper edge.

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: A cast-in-place cylinder bore liner (15) is disclosed for use in sand casting of engine cylinder blocks, the cylinder bore liner (15) having a protuberant portion (60) adjacent a first end (61) thereof, whereby accuracy in the positioning of cast-in-place bore liners (15) is maximized.

Abstract: A mold design is disclosed for sand casting of engine cylinder blocks, such as engine cylinder V-blocks, with cast-in-place cylinder bore liners, wherein a dimensional accuracy in the positioning of cast-in-place bore liners is maximized.

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: 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: 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: A method of fastening core elements together without the use of foreign agencies, such as adhesives, screws or other such fasteners, uses the same core sand and resin that form the core elements themselves. Core sand elements are retained in an assembly by bodies of cured core sand and resin in holes or cavities that span the interface between the core elements and fasten the core sand elements together. Core sand elements are provided with alignable holes, or cavities, into which a mixture of core sand and a curable resin, preferably the same resin used in forming the core sand elements, is added and the curable resin is cured to provide a body of cured core sand and resin, preferably adhering to the core sand elements, fastening the core sand elements together.

Abstract: A solid high silicon cast iron elongated anode has a midpoint electrical connection keeping the connection as far as possible from the ends to combat the deleterious pencil effect. The anode is made by casting using a hollow or shell core to form a small axial hole extending from one end. The sand or foundry material of the core is removed and the wall of the hole at the blind end of the hole is at least partially finished to receive a diagonally split slug to which a lead wire is connected. Alternatively the hole is formed by a steel pipe which is left in place as a hole liner. The pipe may be supported by one or more chaplets. The slug is fastened in the blind end of the hole by a driving tool rotating a threaded headed bolt with both axial and rotational force to hold the connection in the blind end of the hole as it is secured in place. The hole is filled with a potting compound sealing the connection in the center of the solid cast iron anode.

Abstract: A method for preparing an engine block casting having integral cylinder bore liners (10). A barrel slab core (14) includes barrel cores (18). Bore liners (10) surround the barrel cores (18) and are fixed in relation to the barrel slab core (14). A cylinder block mold core package (22) is assembled from the barrel slab core (14), and other cores (24, 26, 28). The liners (10) are heated while they are within the cylinder block mold core package (22) by induction heating. Access holes (30) are defined within the barrel slab core (14), each access hole (30) communicating with the interior of one barrel core (18). A heater (32) is inserted through each access hole (30). Thermal energy is thus transferred across the barrel core (18) to the cylinder bore liner (10) to assure optimum integrity of bonding between a solidified cylinder block casting and the cylinder bore liners (10). The heaters (32) are then retracted before adding the molten metal.

Abstract: This disclosure concerns an expendable core for molds such as die casting dies, which core has a central aperture which may be elongated. The outside of this core is provided with a plurality of parallel grooves across the elongated sides of the core parallel to the aperture. These grooves may have corresponding ribs in the central aperture. One and the common end of each of these grooves is provided with a bridging web integral with the core for reinforcing and strengthening the core. The opposite end of the core from these webs may be provided with a printout portion also integral with the core by which the core is supported in the mold or die.

Abstract: A casting core (42) for forming a water jacket chamber (28) within a cylinder block (22) includes a bonded sand continuous wall portion (48) for forming a water passage (30) encircling a plurality of the cylinders (24) and through which water is circulated for cooling the perimeter of the cylinders (24). The casting core (42) also includes a bridging portion (46) that extends cross-wise in the wall (48) for forming a thin water passage bypass (32) extending through the thin web of cylinder block material (26) separating the adjacent cylinders (24) for providing cooling between the piston cylinders (24). The bridging portion (46) comprises a metal support element (64) covered by a sleeve of woven refractory material (66). A method is also provided for producing a cylinder block having such a casting core (42).

Abstract: A one-piece cylinder head casting, including reliably located passageways for fuel-air intake, for exhaust and for coolant, is formed by a plurality of interengaging one-piece core elements including a one-piece coolant jacket core, a one-piece exhaust core and a one-piece fuel-air intake core, all reliably positioned and held together in an integral core assembly. Preferably, a further core element having a plurality of core supporting and positioning surfaces provides surfaces that mate interfacing surfaces of the one-piece water jacket core, one-piece exhaust core and one-piece intake core and support such cores in position with respect to one another, and the intake core may be provided with a plurality of interfacing surfaces to lock the plurality of core elements into a unitary core assembly. Such cylinder head casting may also be provided with integral walls forming a long, open intake manifold cavity in the side of the cylinder head.

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

Abstract: In a casting core for the water jacket of a cylinder block in a multicylinder, reciprocating-piston internal combustion engine, whose cylinders are arranged in line and are cast in one piece linked by cylinder webs, these webs are provided with rectangular plates of a ceramics material--preferably sintered oxide ceramics--, which are used as supports for two core halves, in which they are anchored in such a way as to present a one-piece casting core. The supports are removed during the core cleaning process, leaving passages for the cooling water.

Abstract: An improved core is adapted to extend axially through the central portion of a mold cavity in which an airfoil or other article is formed. The core is used to form cooling passages as the airfoil is cast in the mold cavity. The core has an elongated cantilevered center section which is disposed within a main or base section. A metallic pin member extends from a free end portion of the cantilevered center section of the core to the main section of the core to hold the free end portion of the cantilevered center section against movement relative to the main section.

Abstract: The method of casting a plate type recuperative heat exchange envelope that encloses a hollow space therein in a single casting operation. A sand core with a heat sensitive binder therein defines the hollow space within the envelope. The sand core is supported by end extensions and lateral protuberances which rest on the sides of a sand mold to provide a space therebetween that is subsequently filled with molten metal to comprise an envelope casting. Lateral openings through the envelope casting produced by the lateral protuberances and end openings produced by the end extensions provide passageways for venting gases produced within the sand core during the casting operation, and after completion of the casting operation the same openings in the envelope assist in the removal of the sand core therefrom. The lateral openings are subsequently plugged while the end openings are maintained open to direct the flow of fluid therethrough.

Abstract: In foundry manufacture of metallic castings it is customary to employ inserts to form elongate ducts whether rectilinear curved or branched ducts and whether of regular cross-section or varying cross-section, including enlarged cavities. A core insert is disclosed which has a wire formed outer tubular casing and an internal wire structure, the core insert being removable in stages. Removal is accomplished by first removing a central longitudinal wire, then any intermediate layer is removed and finally by uncoiling the outer tubular casing, which has preferably previously been wound in such manner and of such diameter wire as to avoid, so far as possible, any exaggerated surface undulations.