Abstract: A die casting system includes a die, a shot tube and a shot tube plunger. The die casting system is positioned relative to a surface. The die includes a plurality of die components that define a die cavity. The shot tube is in fluid communication with the die cavity. The shot tube plunger is moveable within the shot tube to communicate molten metal into the die cavity. Each of the die, the shot tube and the shot tube plunger are inclined at an angle relative to the surface during injection of the molten metal into the die cavity.

Abstract: A die casting system includes a die, a shot tube, a shot tube plunger and a melting unit. The die includes a plurality of die components that define a die cavity. The shot tube is in fluid communication with the die cavity. A shot tube plunger is moveable within the shot tube to communicate a charge of material into the die cavity. The melting unit is positioned relative to the die and includes a bottom portion having an opening for selectively releasing a charge of material through the bottom portion.

Abstract: A molding process utilizes a seed with a columnar grain structure for defining a desired grain structure in a completed casting. The seed is received within a seed cavity of a mold. The molten material adopts the orientation of the columns defined within the seed during solidification to form a completed molded article having a desired columnar grain structure.

Abstract: System and methods involving pattern molds are provided. In this regard, a representative system includes a mold assembly unit having a movable fixture holder operative to engage a portion of a pattern mold and position the pattern mold for assembly.

Abstract: A molding process utilizes a seed with a columnar grain structure for defining a desired grain structure in a completed casting. The seed is received within a seed cavity of a mold. The molten material adopts the orientation of the columns defined within the seed during solidification to form a completed molded article having a desired columnar grain structure.

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: A method of forming a cast component includes at least partially surrounding an investment mold in a heat-insulating packing material, feeding a molten alloy into the investment mold to provide a filled investment mold, and agitating the filled investment mold while solidifying the molten alloy.

Abstract: An investment casting mold article includes a wall for retaining casting material and a cavity defined by the wall. The cavity includes an airfoil portion, a root portion adjacent to the airfoil portion, and a labyrinth seal portion extending from the root portion.

Abstract: Systems and methods for reducing the potential for riser backfilling during investment casting are provided. In this regard, a representative method for performing investment casting includes: providing a mold having an opening communicating with an interior, the interior having a part cavity and a riser; providing an insert; and using the insert to form a physical barrier to reduce a potential for molten metal to backfill into the riser while the molten metal is introduced into the interior of the mold via the opening.

Abstract: A method of forming a gating fixture for a lost wax casting process includes determining an optimal orientation of a gate in relation to a part, and forming a fixture that can repeatably be used to consistently locate the gate relative to the part. In one example, stereolithography is used to form the fixture.

Abstract: In an investment casting process, a composite core is formed as a combination of ceramic casting core element and a non-ceramic casting core element. The core is heated in an oxidative atmosphere and then heated in a non-oxidative atmosphere.

Abstract: A core for investment casting processes includes a core having one or more ceramic materials; and an exterior layer of metal material not susceptible to oxidation under investment casting operating conditions. A method for casting a turbine engine component having an internal passageway includes the steps of forming one or more mold sections each having internal surfaces and at least one of the aforementioned cores for forming one or more turbine engine components having at least one internal passageway; assembling the one or more mold sections; introducing a molten alloy into the one or more assembled mold sections; and consuming the metal of the at least one core during the process.

Abstract: A core for investment casting processes includes a core having one or more ceramic materials; and an exterior layer of metal material not susceptible to oxidation under investment casting operating conditions. A method for casting a turbine engine component having an internal passageway includes the steps of forming one or more mold sections each having internal surfaces and at least one of the aforementioned cores for forming one or more turbine engine components having at least one internal passageway; assembling the one or more mold sections; introducing a molten alloy into the one or more assembled mold sections; and consuming the metal of the at least one core during the process.

Abstract: An induction heated furnace assembly for producing a directionally solidified casting includes a susceptor that tailors strength of the magnetic field within the chamber to provide a desired grain structure in a completed cast part. The susceptor proportionally blocks portions of the magnetic field to provide different levels of magnetic stirring within the molten material at different locations within the furnace assembly stirring induced by the magnetic field is controlled and varied throughout the furnace assembly to create the desired grain structures in the completed cast article.

Abstract: A core for investment casting processes includes a core comprising one or more ceramic materials; and an exterior layer of metal material not susceptible to oxidation under investment casting operating conditions. A method for casting a turbine engine component having an internal passageway includes the steps of forming one or more mold sections each having internal surfaces and at least one of the aforementioned cores for forming one or more turbine engine components having at least one internal passageway; assembling the one or more mold sections; introducing a molten alloy into the one or more assembled mold sections; and consuming the metal of the at least one core during the process.

Abstract: A molding process utilizes a seed with a columnar grain structure for defining a desired grain structure in a completed casting. The seed is received within a seed cavity of a mold. The molten material adopts the orientation of the columns defined within the seed during solidification to form a completed molded article having a desired columnar grain structure.

Abstract: An investment casting mold article includes a wall for retaining casting material and a cavity defined by the wall. The cavity includes an airfoil portion, a root portion adjacent to the airfoil portion, and a labyrinth seal portion extending from the root portion.

Abstract: Systems and methods for reducing the potential for riser backfilling during investment casting are provided. In this regard, a representative method for performing investment casting includes: providing a mold having an opening communicating with an interior, the interior having a part cavity and a riser; providing an insert; and using the insert to form a physical barrier to reduce a potential for molten metal to backfill into the riser while the molten metal is introduced into the interior of the mold via the opening.

Abstract: System and methods involving pattern molds are provided. In this regard, a representative system includes a mold assembly unit having a movable fixture holder operative to engage a portion of a pattern mold and position the pattern mold for assembly.

Abstract: A method of forming a gating fixture for a lost wax casting process includes determining an optimal orientation of a gate in relation to a part, and forming a fixture that can repeatably be used to consistently locate the gate relative to the part. In one example, stereolithography is used to form the fixture.