Abstract: The invention relates to a method for producing a helical metal body (1, 1?), in particular made of aluminum or an aluminum alloy. A blank is first produced in a primary shaping process, a metal forming process, or in a removal process, in particular a machining process, and one or more recesses (100, 101, 201, 202, 203) are then introduced into the blank using a removal process, said recesses defining a circumferential coil, the adjacent windings thereof being mutually spaced, in particular electrically insulated from one another.

Abstract: The invention relates to a casting core for casting moulds, wherein the casting core comprises a central core and a core shroud arranged around the central core. The core shroud contains or consists of ceramic particles bound to a binder. The central core contains or consists of ceramic particles bound to a binder, wherein the ceramic particles of the central core contain or consist of at least one component, which exhibits, at a temperature in a range from 100° C. to 1500° C., a thermally induced phase transformation, and/or at least two components, the thermal expansion coefficients of which at 20° C. differ by at least 5·10?6 K?1. The invention further relates to a method for producing the casting core according to the invention and the use of the casting core according to the invention.

Abstract: The invention relates to a method for producing a helix (2). A permanent mold with mold halves which can be joined together on a mold separation plane is provided. The mold halves of the permanent mold are joined together such that the permanent mold has a cavity, which defines the shape of the helix (2) or the shape of a bent-up helix, when the permanent mold is joined together. The specified helix (2) or the bent-up helix has a flattened profiled winding cross-section which has two opposite flat faces (2.1, 2.1?), an outer face and an inner face (2.3) opposite the outer face. The mold separation plane runs at least partly along the flat faces (2.1, 2.1?) from the inner face to the outer face (2.3), wherein the permanent mold has a bulge (2.5) which extends along the mold separation plane and protrudes into the cavity at least in a region in which the mold separation plane runs along one of the flat faces (2.1, 2.1?) such that the cast body is provided with recesses (2.5) on the flat faces (2.1, 2.1?).

Abstract: A method for producing a spiral-shaped body, in particular an electric coil, made of an electrically conductive material. First, the material is wound about a mandrel in a casting mold in order to form a coil with a plurality of windings, and pressure is then exerted onto the coil in the axial direction of the coil. The pressure leads to a deformation and compression of the cross-section of the individual windings in the axial direction of the coil. By compressing the coil, an optimal use of space is achieved with an electric coil, for example for an electric machine.

Abstract: A method for producing a helical, electrically conducting body. The method including: producing a helical pattern as a lost mold made of a pattern material that can be at least one of liquefied and evaporated under the action of heat; covering the helical pattern with an insulating layer; embedding the helical pattern in foundry sand; pouring a metallic casting material into the lost mold, displacing the pattern material, and bonding with the insulating layer to form a cast body; and removing the cast body, together with the insulating layer adhering thereto, from the foundry sand.

Abstract: The invention relates to a roller casting method for producing a spiral structure, in particular a spiral structure for use in electric machines. Molten metal is supplied between a first roller and a second roller miming opposite thereto, wherein the first roller has first teeth, and the second roller has second teeth, said first and/or second teeth having tooth flanks with cavities for receiving the supplied molten metal. The teeth are designed and aligned such that the cavity of at least one tooth is at least temporarily delimited by the surface of a tooth of the other roller when the rollers are rotating such that the supplied molten metal is molded between the teeth while cooling and is molded into a section of the spiral structure.

Abstract: The invention relates to a method for producing a helix (2), having a step of providing a permanent mold (1) with mold halves (1.1, 1.2) which can be joined together on a mold parting line (1.5). The method additionally has a step of joining together the mold halves (1.1, 1.2) of the permanent mold (1) such that the permanent mold (1) has a cavity (1.3), which defines the shape of the helix (2) or the shape of a bent-up helix (2?), when the permanent mold is joined together, wherein the specified helix (2) or the bent-up helix (2?) has a flattened profiled winding cross-section which has two opposite flat sides (2.1, 2.1?), an outer side (2.2) and an inner side (2.3) opposite the outer side (2.2), and the mold parting line (1.5) runs at least partly along the outer side (2.2) and/or the inner side (2.1) and/or edges of the profiled winding cross-section. The method additionally has a step of removing burrs (3) extending on the outer side (2.2) and/or the inner side (2.

Abstract: The invention relates to a casting mould for producing helical cast bodies (1), in particular coils, springs or spirals, having a mould (10) in the form of a permanent mould which determines the outer contour of the helical body and consists of a ceramic material or is coated by a ceramic material; a supporting tool (8), which supports the mould (10) from outside; and a mould core (12), which defines the continuous opening within the helical body (1) and consists of a ceramic material or is coated by a ceramic material, the mould core being formed in particular as a core puller.

Abstract: The invention relates to a method for producing a coil (6), in which, by means of casting, a semi-finished product (5) in the form of an elongate conductor is formed in a cavity (2) of a casting tool and the coil (6) is formed following a demolding of the semi-finished product (5) by shaping this semi-finished product (5), wherein the form of the semi-finished product (5) may be derived from a shape of the finished coil (6) by stretching along a longitudinal axis of the coil (6) and/or by bending this longitudinal axis, and wherein the semi-finished product (5), during the shaping, is bent and compressed so that windings of the coil (5) already present in the semi-finished product (5) are brought closer to one another at least in some regions during the shaping and are brought into an arrangement along the longitudinal axis of the finished coil (6), wherein the conductor, whilst being shaped, is twisted or bent by no more than a right angle over the course of each individual turn.

Abstract: The present application creates a roller molding method for producing a spiral structure or a coil, in particular a spiral structure for use in electric machines, wherein material is supplied between a first roller and a second roller running opposite thereto, wherein the first roller has first teeth, and the second roller has second teeth, said first and/or second teeth having tooth flanks with cavities for receiving the supplied material, wherein the teeth are designed and aligned such that the cavity of at least one tooth is at least temporarily delimited by the surface of a tooth of the other roller when the rollers are rotating such that the supplied material is molded between the teeth into a portion of the spiral structure or the coil.

Abstract: The invention relates to a method for producing a helical metal body (?), in which initially a preformed, helical metal body is produced in a mould by a casting method and is subsequently compressed along its longitudinal axis by deformation.

Abstract: The present invention relates to a casting core for casting molds, wherein the casting core contains or consists of ceramic particles bound with a silica sol. The casting core has a pore structure, in which the average pore size of the pores increases at least in sections from the outside to the inside in the casting core. The present invention also relates to a method for producing the casting core according to the invention and to the use of the casting core according to the invention.

Abstract: The present invention relates to a casting mold for casting components. The casting mold comprises at least one casting mold frame made of metal and/or of an alloy, and also one or more ceramic casting mold inserts introduced into the at least one casting mold frame. The casting mold insert or the casting mold inserts has/have the negative contour or part of the negative contour of a component to be produced or of the combination of a component to be produced with one or more casting cores. The present invention also relates to a method for producing the casting mold according to the invention and to the use of the casting mold according to the invention.

Abstract: The present invention relates to a casting core for casting moulds, the casting core comprising an inner core and an outer core arranged around the inner core. The outer core contains or consists of ceramic particles bound with a binder. The inner core contains ceramic particles bound with a binder and additionally one or more placeholder elements. The placeholder element(s) is/are at least partially thermally decomposable. The present invention also relates to a method for producing the casting core according to the invention and to the use of the casting core according to the invention.

Abstract: A casting device having a casting mold and a core for producing a helical casting is described. The may have an expendable core that can be dissolved after the casting process. Advantageous effects of the device and process can be achieved by virtue of the fact that the female mold for accommodating the helical casting during the casting process is formed completely within the outer contour of the core, the female mold being delimited by the core and, at the peripheral boundary surfaces of the female mold, by the casting mold.

Abstract: A method for producing a hollow, helical, electrically conducting body. The method comprising: producing a helical core made of a core material that can be at least one of liquefied and evaporated under the action of heat; coating the helical core with a first powder layer of an at least partially electrically conducting powder using a powder coating method; heating the helical core and the first powder layer to a first temperature, at which the helical core is at least one of liquefied and evaporated and at which the first powder layer is at least partially solidified in porous form, the core material exiting space surrounded by the first powder layer; and after the core material has exited the space surrounded by the first powder layer, sintering the first powder layer by heating the first powder layer to a second temperature, which is higher than the first temperature.

Abstract: A casting device having a casting mold and a core for producing a helical casting is described. The may have an expendable core that can be dissolved after the casting process. Advantageous effects of the device and process can be achieved by virtue of the fact that the female mold for accommodating the helical casting during the casting process is formed completely within the outer contour of the core, the female mold being delimited by the core and, at the peripheral boundary surfaces of the female mold, by the casting mold.

Abstract: A method for producing a helical casting pattern. The method including: providing a pattern body having a longitudinal axis, a cavity extending in the direction of the longitudinal axis, and a pattern body wall that surrounds the cavity; providing a processing tool for creating a recess; arranging the pattern body and the processing tool such that the processing tool extends at least partially through the pattern body wall in the radial direction with respect to the longitudinal axis; and rotatably driving at least one of the processing tool and the pattern body about one of the longitudinal axis of the pattern body and an axis parallel thereto, relative to one another, with a relative movement between the pattern body and the processing tool in a direction parallel to the longitudinal axis being produced one of continuously or at least intermittently during or in alternation with the relative rotational movement.

Abstract: A method for producing an electrically conductive component having a cavity is described. An efficient production method for such a component, which allows a high variability of the wall thickness of the component, is implemented by applying a load-bearing layer consisting of an electrically conductive material to a soluble substrate and then dissolving and at least partially removing the substrate.

Abstract: The casting of metals or salt and products made by casting metals or salts are described. For example, a method for casting metals or salts includes evacuating a mold that is pressurized with an inert gas and coupled to a pressurized source of molten metal or salt, wherein the pressurization of the source is sufficiently high to drive the molten metal or salt into the mold in response to the evacuation.