Abstract: A hybrid casting process for structural components uses a re-usable metallic mold rather than a sand mold to produce more consistent cast components. The hybrid casting process uses a metallic mold coupled to a core mold to produce the near net shape of the cast component. Machining operations are performed on the near net shape cast component to produce a final component that meets tolerances and other specifications of the structural component.

Abstract: A hybrid casting process for structural components uses a re-usable metallic mold rather than a sand mold to produce more consistent cast components. The hybrid casting process uses a metallic mold coupled to a core mold to produce the near net shape of the cast component. Machining operations are performed on the near net shape cast component to produce a final component that meets tolerances and other specifications of the structural component.

Abstract: Disclosed is a lost-wax method of casting a product, having steps of: attaching temperature control elements to a wax assembly; encasing the wax assembly and the temperature control elements in a ceramic mold; removing the wax assembly from the ceramic mold; filling the ceramic mold with molten material to form a cast part within the ceramic mold; and separating the ceramic mold and the cast part from each other.

Abstract: A die casting system includes a die having a plurality of die elements that define a die cavity. A charge of material is received in the die cavity. The charge of material comprises a refractory metal intermetallic composite based material system. A die casting method includes casting a component from the refractory metal intermetallic composite based material system.

Abstract: A method of making a composite core includes forming first and second cores of refractory metal and ceramic material. Each of the first and second cores is formed with two layers of a material. The layers are bonded together to form a laminate master pattern, and a flexible mold is formed around the pattern. The pattern is removed from the flexible mold, and slurry material, either pulverulent refractory metal material or ceramic material, is poured into the flexible mold. The slurry material is sintered to form each core. The first core is used as an insert while making the second core to create a final composite core.

Abstract: A method of making an airfoil includes making a refractory metal core that defines an interior of the airfoil by a tomo-lithographic process, making a mold that defines an exterior of the airfoil, inserting the refractory metal core into the mold, and pouring an airfoil material between the refractory metal core and the mold to cast the airfoil.

Abstract: A method of manufacturing a heat shield panel assembly is provided. The method including: injecting melted wax into a negative cavity of a heat shield panel, the heat shield panel including one or more orifices; allowing the wax to solidify to form a positive pattern of the heat shield panel; removing the positive pattern from the negative cavity; coating the positive pattern with a ceramic; melting the positive pattern away from the ceramic, the ceramic having a cavity forming a second negative cavity of the heat shield panel; pouring melted metal into the cavity; allowing metal in the cavity to solidify to form the heat shield panel; removing the ceramic from the heat shield panel; and forming each of one or more threaded studs separately from the heat shield panel, each of the one or more threaded studs including a stud portion and a thread portion simultaneously formed.

Abstract: A method of manufacturing a heat shield panel assembly is provided. The method including: forming a heat shield panel, wherein the heat shield panel includes one or more orifices; and forming each of one or more threaded studs through operations including: injecting melted wax into a negative cavity of a threaded stud; allowing the wax to solidify to form a positive pattern of the threaded stud; removing the positive pattern of the threaded stud from the negative cavity of the threaded stud; coating the positive pattern of the threaded stud with a ceramic; melting the positive pattern of the threaded stud away from the ceramic, the ceramic having a second cavity forming a second negative cavity of the threaded stud; pouring melted metal into the second cavity; allowing metal in the second cavity to solidify to form the threaded stud; and removing the ceramic from the threaded stud.

Abstract: A process for directional solidification of a cast part comprises energizing a primary inductive coil coupled to a chamber having a mold containing a material; generating an electromagnetic field with the primary inductive coil within the chamber, wherein said electromagnetic field is partially attenuated by a susceptor coupled to said chamber between said primary inductive coil and said mold; determining a magnetic flux profile of the electromagnetic field after it passes through the susceptor; sensing a component of the magnetic flux in the interior of the susceptor proximate the mold; positioning a mobile secondary compensation coil within the chamber; generating a control field from a secondary compensation coil, wherein said control field controls said magnetic flux; and casting the material within the mold.

Abstract: An induction furnace assembly comprising a chamber having a mold; a primary inductive coil coupled to the chamber; a layered susceptor comprising at least two layers of magnetic field attenuating material surrounding the chamber between the primary inductive coil and the mold to nullify the electromagnetic field in the hot zone of the furnace chamber.

Abstract: A process for directional solidification of a cast part comprises energizing a primary inductive coil coupled to a chamber having a mold containing a material; energizing a primary inductive coil within the chamber to heat the mold via radiation from a susceptor, wherein the resultant electromagnetic field partially leaks through the susceptor coupled to the chamber between the primary inductive coil and the mold; determining a magnetic flux profile of the electromagnetic field; sensing a magnetic flux leakage past the susceptor within the chamber; generating a control field from a secondary compensation coil coupled to the chamber, wherein the control field controls the magnetic flux experienced by the cast part; and casting the material within the mold under the controlled degree of flux leakage.

Abstract: A process for directional solidification of a cast part comprises energizing a primary inductive coil coupled to a chamber having a mold containing a material; energizing a primary inductive coil within the chamber to heat the mold via radiation from a susceptor, wherein the resultant electromagnetic field partially leaks through the susceptor coupled to the chamber between the primary inductive coil and the mold; determining a magnetic flux profile of the electromagnetic field; sensing a magnetic flux leakage past the susceptor within the chamber; generating a control field from a secondary compensation coil coupled to the chamber, wherein the control field controls the magnetic flux experienced by the cast part; and casting the material within the mold under the controlled degree of flux leakage.

Abstract: High modulus turbine shafts and high modulus cylindrical articles are described as are the process parameters for producing these shafts and cylindrical articles. The shafts/articles have a high Young's modulus as a result of having high modulus <111> crystal texture along the longitudinal axis of the shaft/article. The shafts are produced from directionally solidified seeded <111> single crystal cylinders that are axisymmetrically hot worked before a limited recrystallization process is carried out at a temperature below the recrystallization temperature of the alloy. The disclosed process produces an intense singular <111> texture and results in shaft or cylindrical article with a Young's modulus that is at least 40% greater than that of conventional nickel or iron alloys or conventional steels.

Abstract: An induction furnace assembly comprising a chamber having a mold; a primary inductive coil coupled to the chamber; a layered susceptor comprising at least two layers of magnetic field attenuating material surrounding the chamber between the primary inductive coil and the mold to nullify the electromagnetic field in the hot zone of the furnace chamber.

Abstract: A method of method of making an airfoil includes making a refractory metal core that defines an interior of the airfoil by a tomo-lithographic process, making a mold that defines an exterior of the airfoil, inserting the refractory metal core into the mold, and pouring an airfoil material between the refractory metal core and the mold to cast the airfoil.

Abstract: A process for directional solidification of a cast part comprises energizing a primary inductive coil coupled to a chamber having a mold containing a material; energizing a primary inductive coil within the chamber to heat the mold via radiation from a susceptor, wherein the resultant electromagnetic field partially leaks through the susceptor coupled to the chamber between the primary inductive coil and the mold; determining a magnetic flux profile of the electromagnetic field; sensing a magnetic flux leakage past the susceptor within the chamber; generating a control field from a secondary compensation coil coupled to the chamber, wherein the control field controls the magnetic flux experienced by the cast part; and casting the material within the mold under the controlled degree of flux leakage.

Abstract: A method of fabricating a casting is provided. The method includes creating a mixture of ceramic powder and a binder, pouring the mixture around sacrificial patterns, executing a first thermal treatment to set the mixture into a solid mold without damaging the sacrificial patterns, executing a second thermal treatment to remove the sacrificial patterns without removing any of the binder from the solid mold, executing at least one of a third thermal treatment and a chemical treatment to remove a quantity of the binder to transform the solid mold into a solid breakaway mold and pouring molten metallic material into the solid breakaway mold.

Abstract: An induction furnace assembly comprising a chamber having a mold; a primary inductive coil coupled to the chamber; a layered susceptor comprising at least two layers of magnetic field attenuating material surrounding the chamber between the primary inductive coil and the mold to nullify the electromagnetic field in the hot zone of the furnace chamber.

Abstract: Shot sleeves for high temperature die casting include a low modulus single crystal nickel-based alloy having less than 1 ppm sulfur, a low modulus single crystal nickel-based alloy doped with a sulfur active element, a low modulus single crystal nickel-based alloy having a protective oxide coating, or a combination of two or more of the foregoing.

Abstract: A process for directional solidification of a cast part comprises energizing a primary inductive coil coupled to a chamber having a mold containing a material; generating an electromagnetic field with the primary inductive coil within the chamber, wherein said electromagnetic field is partially attenuated by a susceptor coupled to said chamber between said primary inductive coil and said mold; determining a magnetic flux profile of the electromagnetic field after it passes through the susceptor; sensing a component of the magnetic flux in the interior of the susceptor proximate the mold; positioning a mobile secondary compensation coil within the chamber; generating a control field from a secondary compensation coil, wherein said control field controls said magnetic flux; and casting the material within the mold.