Abstract: A novel cover (10) for one end of the casing within which a vehicular transmission is housed and a unique method for making the cover. The cover (10) has a metallic body portion (12) within which a unitary manifold (40) has been cast in situ. The manifold (40) incorporates a plurality of conduits having artight mechanically crimped ends (A-E) which have been preformed and conjoined into the unitary manifold (40) that is precisely disposed within a mold. Molten metal is admitted into the mold to encapsulate the manifold (40) within the metallic body portion (12) of the cover (10). After the cover (10) has been cast, with the manifold (40) encapsulated therein, the cover (10) is removed from the mold, and only a relatively modest amount of machining operations are required to complete the cover (10).

Abstract: A method and device for making a cylinder block includes a plurality of cylinder liners with flange portions respectively arranged side by side and extending in one direction. Each of the cylinder liners being casted together with a light metal to form a cylinder bore of an engine. The method includes the steps of disposing the cylinder liners within a cavity in a side by side relationship with one another with each of the cylinder liners being held by a core for forming the cylinder bore, forming a material holding section above the flange portions of the two cylinder liners adjacent to each other so as to communicate the two cylinder liners with each other therethrough, introducing a molten material of the light metal into the cavity for making the cylinder block, and removing a solidified material of the light metal in the material holding section. A high quality cylinder block product can thus be obtained.

Abstract: A turbine engine component includes an annular array of airfoils which extend between inner and outer shroud rings. In order to accommodate thermal expansion of the airfoils, space is provided in a shroud ring rail. To provide space in the shroud ring rail, core material is positioned at the ends of the airfoils. The core material may be preformed separetely from the airfoils or may be a coating which is applied to end portions of the airfoils. Wax pattern material partially encloses the end portions of the airfoils and core material. The shroud ring pattern and the core material are covered with ceramic mold material to form a mold. The shroud ring pattern is then removed from the mold to leave the core material disposed in the shroud ring mold cavity at the end portions of the airfoils. As the mold is preheated, bonds between the core material and the airfoils are broken and the core material is gripped between end portions of the airfoils and the ceramic mold material.

Abstract: A method of manufacturing a composite camshaft having a shaft positioned within appropriately aligned and fixtured annular cam and bearing elements, each having interior protrusions that increase in size toward the tube axis. The shaft and elements are supported in a mold and a flowable, hardenable material is injected to fill the space between the tube and the elements for securing the elements to the shaft. The protrusions enhance the grip of the plastic with shrinkage. The shaft and the cam elements have nesting configurations that form a continuous space therebetween such that the hardened material compressionally resists torsional forces between the shaft and cam elements. Injection molding is performed without substantially stressing the freely supported shaft and without applying undue strain to the elements by providing undercut portions in the mold surrounding part of the exterior surface of the elements with high pressure plastic during injection.

Abstract: A pattern for use in casting a rotatable shaft, such as a crankshaft for an internal combustion engine. The pattern includes an evaporable foam pattern section composed of a material such as polystyrene and having a configuration conforming to the crankshaft to be cast. The evaporable foam pattern section includes a plurality of cranks connected by bearing areas, and tubular metal inserts formed of bearing quality steel are disposed around each bearing area and around the pin areas of the cranks. In the casting process, the pattern is placed in a mold and surrounded with a finely divided material such as sand. When molten ferrous metal is fed into contact with the pattern, the pattern will vaporize with the vapor passing into the interstices of the sand while the molten ferrous metal will occupy the void created by the vaporized foam to produce a cast crankshaft having bearing quality steel inserts at the bearing and pin areas.

Abstract: A turbine engine component having an annular array of airfoils disposed between inner and outer shroud rings is made by a method which includes molding bodies of positioning material around central portions of the airfoils. The bodies of positioning material are placed in an annular array. Inner and outer shroud ring pattern dies cooperate with the bodies of positioning material to form inner and outer shroud ring pattern mold cavities. Pattern material is injected into the inner and outer shroud ring pattern mold cavities. The pattern material engages the airfoils, the positioning material, and the shroud ring pattern dies. The pattern material is solidified to form one piece annular inner and outer shroud ring patterns. The shroud ring patterns are covered with a ceramic mold material to form a mold. The inner and outer shroud ring patterns are then removed from the mold to leave shroud ring mold cavities.

Abstract: A composite fastener includes a metal fastener having a shank with an entrant end and an integral insert. A bottom surface of the insert has a greater diameter than the diameter of the shank. The bottom surface also has a lip extending about the periphery of the shank, which during manufacturing of the composite fastener forms a seal against a shuttle for preventing molten material from running down the shank. Further, the insert includes a configuration for supporting a shuttle pin, such as shuttle pin receiving receptacle, to align the metal fastener in a shuttle. A non-corrosive head made of extrudable material, such as zinc, encapsulates the insert.

Abstract: An improved turbine engine component includes an annular array of airfoils which extend between inner and outer shroud rings. In order to accommodate thermal expansion of the airfoils, cavities are provided in one of the shroud rings. The cavities may be formed by moving a shroud ring under the influence of forces applied to the shroud ring by a gating system. The cavities which are formed in the shroud ring to accommodate thermal expansion of the airfoils may be open-ended, completely closed-ended or partially closed-ended. When a turbine engine component having cavities in an inner shroud ring is to be formed, molten metal in an outer shroud ring mold cavity is first solidified to firmly grip outer ends of the airfoils. The molten metal in an inner shroud ring mold cavity is then solidified. As the molten metal in the inner shroud ring mold cavity solidifies, the gating system contracts to pull the metal in the inner shroud ring mold cavity inwardly relative to the airfoils.

Abstract: A turbine engine component includes an annular array of airfoils which extend between inner and outer shroud rings. In order to accommodate thermal expansion of the airfoils, space is provided in a shroud ring rail. To provide space in the shroud ring rail, core material is positioned at the ends of the airfoils. The core material may be preformed separately from the airfoils or may be a coating which is applied to end portions of the airfoils. Wax pattern material partially encloses the end portions of the airfoils and core material. The shroud ring pattern and the core material are covered with ceramic mold material to form a mold. The shroud ring pattern is then removed from the mold to leave the core material disposed in the shroud ring mold cavity at the end portions of the airfoils. As the mold is preheated, bonds between the core material and the airfoils are broken and the core material is gripped between end portions of the airfoils and the ceramic mold material.

Abstract: An improved method of manufacture is provided for producing a channeled wall thrust nozzle (10) of the type used to define a thrust chamber (12) in a jet or rocket engine. The method utilizes a precision formed mandrel (20) having an external geometry conforming generally to the converging-diverging shape of the desired thrust chamber (12), and further including longitudinally extending slots (24) for receiving channel separation ribs (26) which may be formed by die cutting from sheet stock. The channel spaces (16) between the separator ribs (26) are filled with a removable casting material (30) such as wax, and an outer housing shell (32) for the thrust nozzle is mounted about and secured to the separator ribs. The mandrel (20), which is transversely split at the throat of the thrust chamber (12), is then removed to expose the radially inboard margins of the separator ribs (26) for precision machining, followed by mounting of an inner housing shell (34) to the separator ribs.

Abstract: The present invention concerns essentially a method for moulding a rocker arm for an internal combustion engine and the mould structure for carrying out this method, which mould structure comprises a device for maintainiing a ceramic reinforcing element of the arm of the rocker arm co-operating with the cam of a camshaft and comprising a spindle-forming part disposed on the end of the reinforcing element and a pusher-forming assembly located above the spindle-forminig part to forcibly urge the latter against the reinforcing element.

Abstract: The invention relates to a method and apparatus for sand molding composite articles formed of a light alloy metal and fibrous insert. A sand mold is formed containing a fibrous preform separated from the walls of the mold cavity. The mold is fed by means of a tube dipping into a liquid metallic bath therebelow. In the molding process, the pressure in the mold cavity and above the bath are reduced, and the pressure above the bath is increased to create a positive pressure differential .DELTA.P, thereby forcing molten metal from the bath into the mold cavity. The pressure in the mold cavity and above the bath are then increased to above atmospheric, and the pressure differential .DELTA.P is maintained until the metal in the mold cavity solidifies.

Abstract: A method of manufacturing a composite chip-removing tool which includes a tool body of a material which is in its molten state above a predetermined melting temperature, and at least one tipping element secured to the tool body, comprises positioning the tipping element on a model of the tool body that consists of a material that melts at a temperature considerably lower than the predetermined melting temperature, in a position relative to the model which the tipping element is to assume relative to the body, and simultaneously forming the tool body and a durable mechanical connection of the tipping element to the tool body in a precision casting operation involving replacement of the material of the model with the material of the tool body in its molten state. The model may be produced prior to or simultaneously with the positioning of the tipping element on the model.

Abstract: A method for casting molten metal in a mold having integral heat exchange piping. A mold is provided around a pattern, which may be either the disposable or permanent kind. Heat exchange piping is providing by bending seamless carbon steel pipes and placing the pipes into the mold. According to the method of the present invention, during the casting step, the pipes are simultaneously held at selected locations within the mold by hangers that are affixed to the mold, and allowed to expand at their ends into expansion cavities in the mold.

Abstract: The cylindrical side wall of the mold cavity (8) has an inside diameter (D) which is greater than the largest existing ophthalmic lens diameter, and a generally cylindrical membrane (25) of elastomer material is disposed concentrically inside the mold cavity so that in conjunction with the cylindrical side wall of the cavity it defines a variable volume annular chamber (31), the membrane being expansible and retractable radially under the action of a fluid which is alternatively removed from and admitted to the annular chamber.

Abstract: A method for manufacturing a siamese-type cylinder block, which comprises the steps of pouring under pressure a molten metal of aluminum alloy into a siamese-type cylinder barrel molding cavity with an expansion force applied to the sleeve placed in such cavity, and then removing the expansion force after the completion of solidification of the molten metal to cast a cylinder block blank, and subjecting the resulting blank to a working operation for forming the peripheral inner surface of the sleeve into a true circle.

Abstract: A process for casting a cylinder block blank made of light alloy provided with a cylinder barrel reinforced around its cylinder bore with a reinforcing tubular body and a crankcase provided continuous to the cylinder bore, which includes placing the reinforcing tubular body in a first cavity formed for shaping a cylinder barrel at the lower portion of a mold which is formed at its upper portion with a second cavity for shaping a crankcase communicating with the first cavity, and pouring a light alloy molten metal from the lower portion of the first cavity into the first and second cavities while simultaneously venting gas from the first and second cavities.

Abstract: An apparatus (10) for molding metallic articles such as wheel weights (11). Opposed mold sections (108, 109) are carried on support plates (41, 42) that are movable within a stanchion (40) by virtue of an actuating means (45). A feed mechanism (115) delivers mounting clips (18) to one of the mold sections (109), and an escapement means (135) assures that only one clip (18) is delivered at a time. The actuating mechanism (45) sequentially closes the mold sections (108, 109) to form a cavity (100) therebetween, moves the closed mold sections (108, 109) into engagement with an injection tube (79) which mates with a sprue hole (111). The injection tube (79) also presents a positioning lug (180) accurately to rotate the clip (18) to its desired disposition.

Abstract: A method of manufacturing an integral type crankshaft bearing cap for an internal combustion engine. The integral type crankshaft bearing cap comprises crankshaft bearing caps spacedly arranged in the longitudinal direction of the engine and a beam extending in the longitudinal direction of the engine. The manufacturing method comprises making a plurality of models of the crankshaft bearing caps of resin used in full mold casting, arranging the models and connecting the models to the beam, and replacing the resin constituting the models with metal in full mold casting, thereby integrating the replaced metal and the beam.

Abstract: A core assembly is formed by molding a destructible plastic form around at least one insert and optionally around a non-destructible core. The core assembly can be used, for example, for casting engine cylinder heads having valve seat inserts integral therewith. The plastic form retains and supports the inserts until the precise time the plastic is replaced by the molten metal.

Abstract: This invention relates to an elongated heating manifold member for injection molding and a method of making it. Channels are cut into the steel body to run parallel to a hot runner passage extending through the body. An electric heating element is centrally located in the channels using small spacer clips to provide a space around the heating element, and the channels are sealed at the ends. A highly conductive material such as a copper alloy is cast into the space around the heating element in a vacuum furnace. This forms an integral unit with the copper alloy fused to both the heating element and the steel body which substantially improve heat transfer in the manifold member. This avoids the creation of "hot spots" which otherwise may result in the heating element burning out, and maintains an even temperature along the hot runner passage which reduces deterioration of the melt due to overheating.

Abstract: A centrifugal injection machine comprises a rotor arm bearing at each of a pair of free ends a pivotably mounted container. A holder which retains a multiplicity of workpieces is insertable into a capsule or cavity within each container. The rotary arm contains a reservoir associated with each container or liquifying a charge of material. Upon rotation of the machine at a high velocity, the liquified material is transferred from the reservoir to the container in a vacuum and is pressurized therein as a result of centripetal acceleration. Upon the termination of a predetermined interval, a trip mechanism is activated to rotate the containers so that the molten liquid which has not been injected under pressure into recesses in the workpieces is ejected or discharged from the containers. The containers rotate within a vacuum chamber which is depressurized prior to the centrifuge operation.

Abstract: A squeeze formed aluminium alloy article, such as a piston, is formed with a re-entrant cavity (14) with reinforced edges by locating an isostatically compacted salt core (10) and annular alumina-silicate fibre pad (11) in the mould cavity of the squeeze forming press prior to introduction of the molten metal therein. The core (10) is subsequently dissolved from the squeeze formed article to provide a reinforced corresponding shape to the article which does not require subsequent machining.

Abstract: A fiber reinforced metal alloy comprising a metal matrix and a fibrous reinforcement which is constituted by refractory fibers having a high tensile strength. The fiber reinforced metal alloy is manufactured by the use of a centrifugal casting method.

Abstract: The carbon anodes of aluminum reduction cells are suspended on anode rods. The lower part of these rods viz., the anode pins or stubs can be anchored in the carbon anode by pouring cast iron into suitably shaped anode pin or stub holes which are at least partially undercut at the sides.A horizontal layer of cast iron at least some millimeters thick is formed between the floor of the pin or stub holes and the lower face of the anode pins or stubs.The cast iron poured into the spaces around the anode pins or stubs heats these to over 400.degree. C. The mass of the cast iron poured in is smaller than the mass of the lower part of the anode pin or stub to be enclosed.

Abstract: A method of making die castings of one metal with a row of spaced fingers of another metal mounts the fingers in slots of an elongated holder with portions of the fingers projecting beyond the holder. The holder is mounted in a die casting machine having a molding cavity surrounding the projecting portions of the fingers. Metal is die cast around the projecting portions of the fingers to form a frame. The casting and the holder are ejected from the die casting machine, and the holder is stripped from the fingers. The method is especially useful for making relays for teleprinters and the like where electrical input produces mechanical movement and where the fingers become cores of electromagnets with the die casting metal being non-magnetic.

Abstract: A brake crown rotor is produced by casting in a mold the substantially cylindrical cast metal crown, and fusing to the upper portion thereof the outer perimeter of a round prefabricated sheet metal cover, the fusion taking place in the mold.

Abstract: A composite material containing dispersed particles is manufactured by disposing within a mold a porous shaped article of ceramic particles, then pouring a molten metal into the mold, compressing the contents of the mold, subsequently allowing the molten metal to solidify, and subjecting the resultant solidified composite to a plasticizing treatment.

Abstract: A hollow metallic envelope 10 of a finned cast recuperator tube is cast with preformed interior fins 12 and exterior fins 16 integral therewith. A sand core 30 is formed about the preformed interior fins 12 with portions of the fins 12 protruding outwardly from the sand core, and a sand mold 40 is formed to a cavity for receiving the sand core 30 with the preformed exterior fins 16 embedded in the sand mold with portions of the fins 16 protruding therefrom into the cavity. The sand core 30 is placed into the sand mold 40 in spaced relationship therewith so as to provide a clearance space 50 between the sand core 30 and sand mold 40 into which the portions of the interior fins 12 and exterior fins 16 extend. Molten metal is poured into the space 50 which upon cooling solidifies to form the envelope 10 with the interior fins 12 and exterior fins 16 fused integrally therewith.

Abstract: A squeeze formed aluminum alloy article, such as a piston, is formed with a re-entrant cavity (14) by locating an isostatically compacted salt core (10) in the mould cavity of the squeeze forming press prior to introduction of the molten metal therein. The core (14) is subsequently dissolved from the squeeze formed article to provide a corresponding shape to the article which does not require subsequent machining.

Abstract: A method of making a connecting rod for an internal combustion engine which includes shaping a bundle of unidirectional inorganic fibers, placing the bundle into a shaping container and heating it partially in order to fuse the fibers to each other. The partially fused bundle is positioned in a mold in such a manner to produce an extra gap for a predetermined machining allowance between the bundles and cavities. A molten light metal alloy is squeeze cast into the mold under high pressure, i.e., 500-2000 kg/cm.sup.3, forming a matrix annular layer around the bundle. The rod portion of the obtained connecting rod is machined to remove defects in casting, such as a fatigue crack, a blow-hole or mixing of oxidated substances and takes the shape of a circular or elliptical cross-section.

Abstract: A method of manufacturing a piston for internal combustion engines which utilize a core molding or casting system for forming a hollow chamber for the passage of cooling oil therethrough. The manufacturing method includes the steps of preparing a core so as to have at least a first and second foot portion extending therefrom; inserting a bar member made of magnetic materials within each of the first and second foot portions; positioning at least one permanent magnet on a core box; and fixing the core to the core box via the bar members due to the magnetic flux of the permanent magnet.

Abstract: A metal golf club head is provided, by an investment casting process, having an accurately positioned weighting insert of heavy metal rigidly embedded in and surrounded by the principle metal of the head with the presence of the insert, if desired, being entirely or substantially undetectable from a visual inspection of the finished head.

Abstract: An improved method of manufacturing a swash plate assembly for use in a compressor, fluid motor or similar device in which a plurality of pistons are connected, by means of connecting rods, to a swash plate which drives (or is driven by) the pistons. A plurality of ball ended rods of a predetermined length having a pair of split die-inserts positioned about the rod, each against one of the balls. The balls are positioned in a die means having a central core to locate their position and which die means securely maintains the inserts against each of the ball ends. About one ball end of the rod, a piston with or without a slot is cast and the opposite ball end, which is positioned in a mating swash plate socket, has a swash plate cast about it. The finished assembly is machined for overall length, surface parallel, and, angular and diametral relationships.

Abstract: A connecting rod for a radial piston motor including a spherical surface portion, a rod portion and a pad portion having a sliding surface. The spherical surface portion, rod portion and pad portion are formed integrally, and the sliding surface has a bearing alloy attached to its surface by centrifugal casting. An overlay may be provided on the bearing alloy. The connecting rod is produced in a mass production basis by a method including the steps of integrally forming a star-shape cylindrical monolithic blank (18) having a single cylindrical centrally located axial opening and bearing six equally spaced outwardly radiating rod portions (2), each rod portion bearing an integral, substantially spherical surface portion (1) on its distal end; attaching a bearing alloy by centrifugal casting, to the centrally located axial opening in said blank (18); machining the surface of the bearing alloy; and dividing the blank into six pieces constituting six connecting rods.

Abstract: A method and apparatus for casting straps onto the plate lugs of battery cell elements. The apparatus includes a rotatably indexable table having a plurality of mold and element carrying stations which each are successively indexed through a plurality of operating stations, including an element loading station, an element lug alignment station, a molten-metal pouring station, a lug fluxing station, a casting station, a plurality of mold cooling stations, and an element unloading station. The mold of each table station is adapted for efficient and precisely controlled electrical resistance heating and forced-air cooling during each cycle of operation. In the illustrated embodiment, each table-station mold is successively heated from electrical sources at a plurality of operating stations upon indexing of the respective table station to such operating stations and is cooled by directing air through air-direction tubes mounted on each table station in close proximity to the respective mold.

Abstract: An improved method of manufacturing a swash plate assembly for use in a compressor, fluid motor or similar device in which a plurality of pistons are connected, by means of connecting rods, to a swash plate which drives (or is driven by) the pistons. A plurality of piston and rod assemblies are made by casting the piston around one end of a connecting rod which is formed with a ball at both ends, thus providing a ball-socket connection therebetween. The pistons are finish machined. A die-insert is utilized to locate the ball and rod prior to casting, and is thereafter moved along the rod to contact the other ball end. This insert thus serves to locate the rod section with the affixed piston in a mating socket of a swash plate die. The swash plate is cast about a plurality of such piston bearing rods to a carefully toleranced dimension. The swash plate end of the assembly is then finish machined.

Abstract: The wear resistant insert is an annular ring of austenitic iron alloy. It has a peripheral surface which conforms to the exterior of the piston into which it is to be cast. A plurality of frangible tabs project outward from the periphery. When casting a piston, the insert is supported on a ledge in a die cavity. A predetermined amount of aluminum alloy is poured into the die cavity and the cavity is closed by a punch. The punch applies a force on the solidifying alloy. As the aluminum alloy shrinks during solidification, the pressure severs the frangible tabs allowing the insert to shift.

Abstract: The disclosure relates to a method of manufacturing a gas turbine rotor or stator using elastomeric rings for the retention of the rotor or stator blades in a core mold. The elastomeric rings are split to facilitate disassembly thereof from the blade core which is thereafter utilized in a cope and drag casting system.

Abstract: An improved method of manufacturing a swash plate assembly for use in a compressor, fluid motor or similar device in which a plurality of pistons are connected, by means of connecting rods, to a swash plate which drives (or is driven by) the pistons. A plurality of piston assemblies are made by casting the piston around one end of a connecting rod section which is formed with a ball thus providing a ball-socket connection therebetween. Mating spherical ends with through-bores to receive the piston connecting rod section are cast-in-place and captured in sockets within the swash plate. The connecting rod section of the pistons is mated to the through-bores of the mating spherical ends and are positioned in an appropriate fixture to a fixed final relationship. The connecting rod sections are secured to the sidewall of each through-bore by a means such as electron-beam welding to secure the overall length of the final assembly.

Abstract: This invention relates to an improved method of manufacturing a heater nozzle for an injection molding system. The heater nozzle has a helical heating element which is cast into an outer portion around an inner liner through which the melt flows. The outer portion is formed of a conductive material such as a beryllium copper alloy and the inner liner is formed of a durable corrosion resistant material such as stainless steel to provide an excellent combination of these characteristics. The heater nozzle is made by positioning the heating element around a pre-heated solid threaded liner in a mold and pressure casting the beryllium copper outer portion around them. The elongated liner is very accurately located in the mold by having the lower end received in a seat in the mold and the upper end received in an aperture through the plunger as it closes.

Abstract: A method of making a die cast aluminum based engine block with a closed deck is disclosed. A core assembly having at least one water soluble alkaline metal salt core member is stationed on a bore die of a die casting assembly for the block. The core assembly also preferably comprises an iron cylindrical liner centered within the salt core member by an aluminum mesh collar which dissolves in the cast metal during high pressure aluminum die casting. The salt core member is fabricated by die casting under pressure and heat to form a shaped body which, as a core, cooperated to define a substantially closed chamber to serve as the water jacket for the block. The salt core member is removed from the cast block by water dissolution admitted through small port openings in the closed deck block to form a brine, which brine is then washed out of such port openings.

Abstract: A method and apparatus for manufacture of brake drums, particularly tri-metallic drums of the type comprising a preformed brake liner, a mounting disc, and an aluminum shell cast around and joining the liner and disc into a rigid structure. The apparatus includes a mandrel with a plurality of springs for internally resiliently engaging the brake liner and locating the same in accurate position. The mounting disc is likewise accurately positioned on a mold surface, and the mold is closed to form a cavity for casting of the shell coaxially with the liner and disc.

Abstract: A metal-capped electrical insulator and method of making same by forming a metal cap on an insulator dielectric by directly casting molten metal round a portion of the dielectric to embed it therein. Before casting the metal (16 or 17), a metal washer (1 ) is placed in contact with the boundary on the insulator at the edge of the portion to be embedded. The washer has a circular groove (2) open on the side through which the molten metal is poured. Before casting, said washer is deformed, by pressing it hard in a metal-casting mould (30) to the dielectric and deflecting the walls (3, 4) of the groove (2) to create an undercut in the metal washer.

Abstract: An aerofoil member such as a blade or vane for a gas turbine engine comprises a hollow aerofoil with a plug of porous material filling a region of the hollow interior. The porous material forms at least part of the external surface of the aerofoil so that cooling fluid can flow from the interior of the aerofoil through the plug to the external surface of the aerofoil. The plug is preferably at the leading or trailing edge of the aerofoil. Methods of making the member include investment casting using a porous ceramic core to form the porous plug, or using sintered particulate material to form the porous plug.

Abstract: A fluid cooled blade or vane for use in a gas turbine or like apparatus is disclosed herein. The blade or vane includes an elongated open ended skin of predetermined cross-sectional configuration, a number of spaced cooling tubes located within and extending in the elongated direction of the open ended skin, a reinforcement spar disposed within the skin along with tubes, and solid material, preferably copper, filling the elongated skin around the tubes and spar. A specific method of making the blade or vane just described is also disclosed and includes initially providing the elongated skin as a preform. The cooling tubes and spar are disposed within the preform in their intended positions. Thereafter, the filling material while being maintained in a molten liquid state is caused to flow into the remaining space within the preform around the tubes and reinforcement spar. At the same time, this molten material is prevented from entering the tubes.

Abstract: A method of casting a hollow bodied plate type recuperative heat exchange envelope. The heat exchange envelope comprises first and second envelope halves cast independently, then bonded together by fusion of molten metal of the second envelope half with solidified metal of the first envelope half. The first envelope half includes a lateral flange on opposite sides thereof that is confronted by the molten metal of the second envelope half to form a flange that connects envelope halves providing an increased area of contact therebetween. The flange of the second envelope half includes multiple surface areas that become fused to opposite sides of the first envelope half to form a strong connection impervious to fluid leakage.

Abstract: An apparatus and method for producing ingot mold caps is provided in which a shaped opening in a chill element is lined with a pre-formed refractory/ceramic fiber pad and metal is cast in the lined opening around a cored lift engaging means.

Abstract: Apparatus and method for injecting molten lead from a reservoir into a die mold cavity formed about an aperture in the wall of a plastic battery for casting lead-alloy battery terminal connectors. Batteries are positioned adjacent the molten lead reservoir of the apparatus and mold portions move together to hold the battery containers in a clamp-like action. Molten lead is die cast under pressure into the mold cavity in which a stainless steel threaded nut is positioned. The lead is forced through a heated chamber into a portion of the mold which may be water cooled. The mold is designed to allow venting of gases, thereby eliminating porosity; and the apparatus is designed to provide casting which is free of jagged projections in the sprue hole.

Abstract: A method of manufacture of novel light-weight pistons of aluminum forgings with an integral iron insert ring by fusion welding is described. The aluminum piston forging is provided with a configuration adapted to receive the iron insert ring which may be coated to provide an inter-metallic joining alloy. The configured piston forging is placed in a mold, the ring is positioned in the configuration. The mold is rotated and molten alloy is introduced at an angle to deoxidize the forging and the ring, sweep the oxides to non-critical areas of the mold and to join the forging to the ring upon cooling to form a fusion weld.