Abstract: A method for casting a thrower for a railcar coupler includes creating a mold box that is vertically parted in halves, each half defining a side of a thrower cavity and that includes at least a portion of a sprue at a location above the thrower cavity, the thrower cavity also being oriented vertically; pouring molten metal into the mold box through the sprue and into the thrower cavity while the mold is oriented vertically; and shaking out the mold box to release the thrower after the thrower has cooled. Creating the mold box may be executed through a cold shell process. The halves of the mold box may include reflective images of the sides of two thrower cavities and an ingate connected between the sprue and one of the two thrower cavities.

Abstract: A multi-wall ceramic core for casting an airfoil with one or more internal cooling passages is made by preforming at least one fugitive core insert, then forming at least one core insert in-situ adjacent and fused to the at least one preformed core insert by introducing fluid fugitive pattern material into a composite core insert mold whereby the fugitive core inserts are integrally connected as a single composite core insert that includes features to form internal passage surfaces in the core when the composite core insert is removed. The composite core insert is placed in a core molding die cavity, and a fluid ceramic material is introduced into the die cavity to form the ceramic core body incorporating the fugitive composite core insert therein.

Abstract: In order to produce molds or cores for foundry purposes from a mixture (M) of molding compound or sand and at least one binder, the mixture is mixed (M) by a mixing device (20) and is fed with the aid of a feeding system (30) to at least one sand storage unit (40) of a core or mold production device (50), wherein the mixture-free region (21) of the mixing device (20), at least at times, and/or the feeding system (30) located between the mixing device (20) and the core or mould production device (50), and/or the sand storage unit (40) downstream of the feeding system (30) and upstream of the core or mould production device (50), is moistened or kept moist by means of a liquid (71). The liquid (71) used for moistening is atomised by at least one ultrasonic atomiser (60) to form a suspended aerosol and is fed to the mixing device (20) and/or the feeding system (30) and/or the sand storage unit (40) via pipes (81, 82, 83).

Abstract: A rapid manufacturing method includes forming tooling in a rapid manufacturing process. The tooling is coated with a conductive material.

Abstract: An aluminum-based diesel engine piston and a method of making the piston. The method involves casting the piston with complex geometries, including undercut or reentrant features. The casting uses an aggregate disposable mold that can be removed from the as-cast part. In one form, the complex geometry includes an undercut combustion bowl formed in the piston dome, while in another, it may include an internal cooling passage. The undercut bowl and internal passages may be produced using the aggregate disposable mold.

Abstract: A method of casting a core includes the steps of preparing a first half of a corebox, preparing a second half of a corebox such that the parting line of a core formed from the first and second coreboxes runs along the vertical axis of the core.

Abstract: In the sand core 10, the tar reducing agent is included in at least the second coating layer 13, which is the outermost layer, of the coating layers 12 and 13. Thus, the tar, which may be generated from the core body 11 and the coating layers 12 and 13 which are positioned thereinside, can be decomposed into low molecular gases (carbon monoxide, carbon dioxide, water, and the like) by heat of the molten metal. As a result, generation of the tar from the sand core 10 to the outside can be prevented. In this case, since the layer which includes the tar reducing agent is the second coating layer 13 which directly contacts the molten metal, the second coating layer 13 can directly receive the heat of the molten metal, and the tar generation prevention effects can be thereby remarkably obtained. Therefore, generation of defects in cast products which may be caused by clogging in the gas drain can be prevented, and structures of the gas drain of the die and the surroundings thereof can be simplified.

Abstract: We describe a lattice part made of metal and a method for producing a lattice part made of metal or a metal alloy. The lattice has a thickness of less than 1 mm at a size of the gaps of less than 50 mm2. The lattice (5) comprises a connection made of knots, and perpendicular to the lattice surface has lattice bars and lattice knots of the same thickness. A method for the production of a lattice part made of metal, particularly made of light alloy, is characterized by a primary shaping process according to DIN 8580, wherein a mold is formed in the first step, a primary material is introduced in the mold cavity in the second step, the part is removed from the mold in the third step, and the finishing of the metallic lattice part is carried out in the fourth step.

Abstract: A method of fabricating a decomposition conduit with an in-line static mixer, the method comprising molding a decomposition conduit housing around a sand core by inserting molding material into a cavity between a decomposition conduit housing mold and the sand core, where the sand core includes a static mixer and, where the act of molding the decomposition conduit housing is operative to mount the static mixer to the molded decomposition conduit housing.

Abstract: A support material for use with a digital manufacturing system, the support material comprising at least one inorganic ionic compound and is configured to be deposited with the digital manufacturing system using a layer-based additive technique to form a support structure for supporting at least one overhanging region of a three-dimensional model built with the digital manufacturing system.

Abstract: A molding process and a flaskless molding machine for simultaneously making an upper flaskless mold and a lower flaskless mold are provided such that the bottom surfaces of the molds can be in a stable and horizontal position, the stripping of the flasks can be reliably carried out, and the configuration of the molding machine can be simplified.

Abstract: A casting core assembly includes a metallic core and a ceramic core. The process for forming the casting core assembly includes inserting a ceramic plug of a metallic core and ceramic plug core subassembly into a compartment of the ceramic core. The ceramic plug is secured to the ceramic core.

Abstract: A sprue for use in investment casting may comprise a pin and a shell enclosing a part of the pin. A method for creating a sprue may comprise partially enclosing a pin in a shell.

Abstract: A bi-cast turbine rotor disk and method of forming the same are provided. The disk includes a ring and a blade. The ring comprises a superalloy that includes a plurality of elements, and the blade extends from the ring. The blade comprises a non-metallic ceramic matrix composite, and at least one element from the superalloy of the ring is diffused into the non-metallic ceramic matrix composite of the blade.

Abstract: Methods, systems and compositions for manufacturing downhole tools and downhole tool parts for drilling subterranean material are disclosed. A model having an external peripheral shape of a downhole tool or tool part is fabricated. Mold material is applied to an external periphery of the model. The mold material is permitted to harden to form a mold about the model. The model is eliminated and a composite matrix material is cast within the mold to form a finished downhole tool or tool part.

Abstract: The object of the present invention is to provide a method for green sand molding that prevents a bad casting by producing a mold that does not have a brittle surface. The method comprises the steps of filling the green sand into a flask while fluidizing the green sand by aeration at a pressure between 0.05 and 0.18 MPa, and squeezing the green sand that has been filled in the flask, wherein a mold is produced so that the friability of the mold is 10 or less. The friability is a value that is calculated by the following steps: putting the mold in a rotating cylindrical sieve that has a diameter of 177.8 mm and USA sieve size No. 8, rotating the cylindrical sieve at 57 rpm for 60 seconds, dividing the weight of the sand that has passed through the sieve by the weight of the sand that has been put into the sieve, and multiplying the quotient by 100.

Abstract: Described are methods for making microstructured flexible molds, for example useful for making microstructured metal objects in a casting process. Also described are casting methods for making microstructured epoxy objects. In some embodiments, the microstructured metal and epoxy objects are useful for embossing polymer sheets to form microstructured polymer sheets.

Abstract: A diesel engine piston and a method of making the piston. The method involves casting the piston with complex geometries, including undercut features. The casting uses an aggregate disposable mold that can be removed from the as-cast part. In one form, the complex geometry includes an undercut combustion bowl formed in the piston dome, while in another, it may include an internal cooling passage. The undercut bowl and internal passages may be produced using the aggregate disposable mold.

Abstract: There is provided a method for manufacturing a three-dimensional shaped object. The method of the present invention comprises the repeated steps of: (i) forming a solidified layer by irradiating a predetermined portion of a powder layer with a light beam, thereby allowing a sintering of the powder in the predetermined portion or a melting and subsequent solidification thereof; and (ii) forming another solidified layer by newly forming a powder layer on the resulting solidified layer, followed by the irradiation of a predetermined portion of the powder layer with the light beam; wherein only the surface portion of the solidified layer, to which a force is applied when the three-dimensional shaped object is used, is subjected to a machining process.

Abstract: The invention relates to sand casting and more specifically to sand casting of a heat exchanger element with pins and/or fins. The invention provides a core box for sand casting of workpieces comprising pins and/or fins. The core box molding surface comprises at least one air vent and pins and/or fins. The at least one air vent is integrated in at least one pin or fin.

Abstract: A metal article containing at least 10% interconnected porosity is produced by using a preform. To make the preform, an organic binder, a wetting agent and a granular material are mixed to obtain a mouldable paste that combines 10 vol. pct. or more of the granular material, this material dissolving easily in a liquid solvent. The paste is shaped into an aerated preform, thus creating an open pore space to be infiltrated by the metal or alloy. The wetting agent is evaporated and the preform is baked to a temperature sufficient to degrade the binder and create a network of interconnected open porosity in the preform. Then, the open pore space is filled with the liquid metal or alloy. All or part of the baked preform can be easily leached by a liquid solvent through the network of fine pores.

Abstract: Integral liquid-coolant passageways in an x-ray tube. In one example embodiment, an x-ray tube includes a can at least partially defining an evacuated enclosure, a cathode at least partially positioned within the evacuated enclosure, and an anode at least partially positioned within the evacuated enclosure. The can has first integral liquid-coolant passageways formed therein. The can is configured to have a liquid coolant circulated through the first integral liquid-coolant passageways to thereby cool the can without the can being submersed in a liquid coolant.

Abstract: A molding process which comprises mixing together a particulate aggregate, plural kinds of water-soluble binders, a crosslinking agent causing crosslinking reaction with the binders, a phenol resin, and water, agitating the obtained mixture to prepare a bubbled fluid aggregate mixture, filling the aggregate mixture into a molding cavity, and solidifying the aggregate mixture through the evaporation of water from the mixture to give a mold made from the mixture.

Abstract: A support frame for use in a wind turbine including a tower and a rotor that is rotatably coupled to a rotor shaft. The support frame includes an upper portion including an inner surface, an outer surface, and at least one bearing housing that is sized to receive the rotor shaft therethrough. A lower portion is integrally formed with the upper portion and extends from the upper portion. The lower portion includes a support flange that is configured to be coupled to the tower to support the rotor shaft and the rotor from the tower.

Abstract: Methods of reducing the permeability of a subterranean formation to aqueous-based fluids using a water-soluble relative permeability modifier that comprises a hydrophobically modified polymer, wherein the hydrophobically modified polymer is a reaction product of: a hydrophilic polymer that comprises a polymer selected from the group consisting of a polyvinylamine, a poly(vinylamine/vinyl alcohol), and an alkyl acrylate polymer; and, a hydrophobic compound comprising at least one alkyl chain having a carbon chain length between about 4 and about 22 carbons. The water-soluble relative permeability modifier may be placed within a subterranean drilling operation such that the water-soluble relative permeability modifier attaches onto surfaces within the subterranean formation to effect permeability of aqueous fluids.

Abstract: Described is a procedure for layered composition of models, whereby at least a first material is applied to an assembly platform, followed by selective application of a second material layer; these two application steps are repeated until the required model is achieved and both materials form a solid structure in an appropriate mixture ratio. The first material comprises a moulding sand; the first and/or second material comprises a bonding agent encompassing a salt-crystal binder and/or protein binder.

Abstract: There are provided a dry aggregate mixture wherein the binder, even when heated, does not evolve unpleasant odor or gas hazardous to human health; a method of foundry molding wherein a space for foundry molding, up to minute portion thereof, can satisfactorily be filled with an aggregate mixture composed of a binder and granular aggregate; and a method of foundry molding wherein the mold used in molding of an aggregate mixture composed of a binder and granular aggregate can retain satisfactory properties even in high humidity. In the method of foundry molding, a mold is formed by the use of a dry mixture obtained by providing an aggregate mixture composed of granular aggregate, a water soluble binder and water and evaporating the water contained in the aggregate mixture through heating, pressure reduction or aeration while mixing so as to effect separation into single granules, or with the addition of a lubricant and a crosslinking agent thereto.

Abstract: There are provided a dry aggregate mixture wherein the binder, even when heated, does not evolve unpleasant odor or gas hazardous to human health; a method of foundry molding wherein a space for foundry molding, up to minute portion thereof, can satisfactorily be filled with an aggregate mixture composed of a binder and granular aggregate; and a method of foundry molding wherein the mold used in molding of an aggregate mixture composed of a binder and granular aggregate can retain satisfactory properties even in high humidity. In the method of foundry molding, a mold is formed by the use of a dry mixture obtained by providing an aggregate mixture composed of granular aggregate, a water soluble binder and water and evaporating the water contained in the aggregate mixture through heating, pressure reduction or aeration while mixing so as to effect separation into single granules, or with the addition of a lubricant and a crosslinking agent thereto.

Abstract: A spherical casting sand having an average particle diameter of 0.03 to 1.5 mm, produced by a flame fusion method, usable together with a urethane binder. Casting sands capable of producing a mold having higher strength and excellent surface smoothness without deformation or breakage with fewer gas defects in producing a mold by using a urethane binder in the cold box process or in the urethane self-hardening mold making method. The casting sand has longer bench life in the cold box process. Amount of generated gas that is a problem of the mold making method using a urethane binder can be significantly reduced, and a casting with fewer gas defects can be obtained.

Abstract: An investment casting process for a hollow component such as a gas turbine blade utilizing a ceramic core (10) that is cast in a flexible mold (24) using a low pressure, vibration assisted casting process. The flexible mold is cast from a master tool (14) machined from soft metal using a relatively low precision machining process, with relatively higher precision surfaces being defined by a precision formed insert (22) incorporated into the master tool. A plurality of identical flexible molds may be formed from a single master tool in order to permit the production of ceramic cores at a desired rate with a desired degree of part-to-part precision.

Abstract: An investment casting process wherein the wax pattern tool (44) is flexible to facilitate removal of the tool from the cast wax pattern (52) even when the cast shape would otherwise require multiple pull planes. The flexible tool may include a flexible insert (42) precisely indexed to a surrounding coffin mold (40), and thereby to an enclosed ceramic core (10). Positioning pins (106) may extend from the flexible tool to make compliant contact against the core prior to a wax injection step. The surface of the resulting wax pattern may contain an engineered topography (36) replicated through the flexible surface from a master tool (12). The flexible tool may encase thermally conductive or magnetic particles (92), or other active device (96) such as a sensor or vibrator which is operable during wax injection.

Abstract: In the sand core 10, the tar reducing agent is included in at least the second coating layer 13, which is the outermost layer, of the coating layers 12 and 13. Thus, the tar, which may be generated from the core body 11 and the coating layers 12 and 13 which are positioned thereinside, can be decomposed into low molecular gases (carbon monoxide, carbon dioxide, water, and the like) by heat of the molten metal. As a result, generation of the tar from the sand core 10 to the outside can be prevented. In this case, since the layer which includes the tar reducing agent is the second coating layer 13 which directly contacts the molten metal, the second coating layer 13 can directly receive the heat of the molten metal, and the tar generation prevention effects can be thereby remarkably obtained. Therefore, generation of defects in cast products which may be caused by clogging in the gas drain can be prevented, and structures of the gas drain of the die and the surroundings thereof can be simplified.

Abstract: The invention relates to a size composition (coating composition) for casting moulds and cores, comprising at least one metal additive which contains a metal or a compound of a metal, wherein the metal is selected from one of groups 7 or 9 to 12 of the Periodic Table of the Elements. The invention also relates to a process for producing a casting mould, which comprises a mould coating of the size (coating) according to the invention, and to the use of said mould for the casting of metals.

Abstract: A process for repairing one or more worn inlet ports on an interior or exterior surface of an extruder die wherein each inlet port provides an opening into an extrusion channel. The worn inlet port has a funnel shape and a diameter greater than that of the extrusion channel. The worn inlet port is repaired by placing a fused silicon oxide insert into one or more extrusion channels so that an external surface of the insert engages the interior surface of the extrusion channel, thereby forming a pocket around the insert between the circumference or perimeter of the worn inlet port and the external surface of the insert. The pocket is filled with molten metal, and the insert prevents the molten metal from entering the extrusion channel. When the molten metal hardens the inserts are removed. New inlet ports are thereby formed having the same diameter as the extrusion channels.

Abstract: A knuckle for a railway coupler system is made without internal voids or cores. Instead, external pockets are formed on the front face and tail portion surface to reduce weight. The knuckle is formed by investment casting, which permits a pulling face to be provided without a draft angle or parting line typical of a cast part. As a result of these innovations, the knuckle according to the invention has an improved fatigue life.

Abstract: Yokes utilized in railway coupling apparatus are designed according to the invention to have improved stress profiles and increased service life. Investment casting techniques used to make the yokes and other components of the coupling apparatus yield improved surface finishes and tighter dimensional tolerances of the parts without requiring hammering, coating or other post-casting treatment.

Abstract: A low lead brass alloy and a method for producing a product comprising the low lead brass alloy are proposed. The low lead brass comprises 0.05 to 0.3 wt % of lead (Pb); 0.3 to 0.8 wt % of aluminum (Al); 0.01 to 0.4 wt % of bismuth (Bi); 0.1 to 0.15 wt % of microelements; and more than 97.5 wt % of copper (Cu) and zinc (Zn), wherein copper is in an amount ranging from 58 to 70 wt %.

Abstract: An intermediate stalk (10) that is used for a low-pressure die-casting apparatus includes a metal covering material (2), and a precast refractory material (1) that is removably fitted into the metal covering material (2), an air release opening (3) being formed between the metal covering material (2) and the precast refractory material (1) when viewed from above. According to the present invention, an intermediate stalk that allows water to be sufficiently released from the refractory heat insulator during heating, does not explode, does not produce cracks in the refractory heat insulator due to the difference in coefficient of thermal expansion between the refractory heat insulator and the metal covering material, and allows easy replacement of the refractory heat insulator, a method of producing the same, and a low-pressure die-casting apparatus can be provided.

Abstract: Three dimensional printing equipment and techniques may be used in combination with three dimensional design data associated with well drilling equipment and well completion equipment to form molds associated with manufacture of such equipment. For example, such molds may be used to form a bit body or other components associated with a rotary drill bit. For some applications composite or matrix materials may be placed in the mold to form a matrix bit body. Heat transfer characteristics of the mold may be optimized for heating and/or cooling of the matrix materials to provide optimum fracture resistant (toughness) and optimum erosion, abrasion and/or wear resistance for portions of the bit body. Such molds may also be used to form steel bit bodies associated with fixed cutter rotary drill bits and other components associated with a wide variety of well drilling equipment and well completion equipment.

Abstract: Three dimensional printing equipment and techniques may be used in combination with three dimensional design data associated with well drilling equipment and well completion equipment to form molds associated with manufacture of such equipment. For example, such molds may be used to form a bit body or other components associated with a rotary drill bit. For some applications composite or matrix materials may be placed in the mold to form a matrix bit body. Heat transfer characteristics of the mold may be optimized for heating and/or cooling of the matrix materials to provide optimum fracture resistant (toughness) and optimum erosion, abrasion and/or wear resistance for portions of the bit body. Such molds may also be used to form steel bit bodies associated with fixed cutter rotary drill bits and other components associated with a wide variety of well drilling equipment and well completion equipment.

Abstract: A sand-forming apparatus (10) comprising a box (20), a blow tube assembly (50) and a bonnet (90). The box (20) has a cope (30) and a drag (40) which together define a cavity (21) having a shape corresponding to a desired sand-shape. The blow tube assembly (50) comprises a blowplate (55), and at least one tube (50). The bonnet (90) may be fixed to and movable with the blowplate (55). Relative movement between the cope (30), the blowplate (55) and/or the bonnet (90) converts the apparatus (10) between a sand-blowing state and a catalyst-introducing state.

Abstract: New methods and systems for manufacturing a three-dimensional form, comprising steps of providing a plurality of particulates; contacting the particulates with an activation agent; contacting particulates having the activation agent with a binder material that is activatable by the activation agent; at least partially hardening the binder for forming a layer of the three-dimensional form; and repeating these steps to form the remainder of the three-dimensional form. Following sequential application of all required layers and binder material to make the form, the unbound particles are appropriately removed (and optionally re-used), to result in the desired three-dimensional form. The invention also contemplates a novel method for preparing a form, where unbound particulates free of binder material are re-claimed.

Abstract: A rotor for an induction motor and a method of preparing same. The method includes making a squirrel-cage rotor made up of a cage and a laminate stack by forming a mold around the stack, heating the stack and introducing a molten metal into the mold such that the molten metal substantially fills a space defined in the stack that corresponds to the cage. In one form, the space includes slots or related channels formed in the stack that upon filling with the molten metal become longitudinal bars that form electric current loops with end rings of the cage. By heating the stack and maintaining it at a temperature high enough to keep the molten metal in a substantially molten state at least long enough for it to flow through the slots of the stack, premature freezing of the molten metal is avoided. In addition, by providing low pressure to the molten metal in conjunction with the elevated temperature in the stack, flow is promoted to ensure a substantially porosity-free, fully dense squirrel-cage for the rotor.

Abstract: An exemplary method for forming a sand core includes forming a core insert; forming a sand core precursor around the core insert; and creating at least one passage within the sand core precursor by removing or otherwise transforming a portion of the core insert, wherein the at least one passage includes at least one exit point. The sand core may then be utilized in a casting mold assembly to form a cast part.

Abstract: A ceramics particle produced by a flame fusion method, containing MgO and SiO2 as main components, and having a MgO/SiO2 weight ratio of from 1.0:1 to 1.45:1, and an average particle size of from 0.001 to 1.5 mm; a spherical molding sand containing MgO and SiO2 as main components, and having a MgO/SiO2 weight ratio of from 1.0:1 to 1.45:1, and an average particle size of from 0.001 to 1.5 mm, produced by a flame fusion method; a spherical molding sand, comprising MgO and SiO2 as main components, and having a MgO/SiO2 weight ratio of from 1.0:1 to 1.45:1, an average particle size of from 0.001 to 1.5 mm, and a spherical degree of 0.95 or more; a process for producing the above spherical molding sand; a casting mold containing the spherical molding sand as defined above; and a casting produced by casting with the mold as defined above.

Abstract: A sand based mold and method for casting a device having a cavity. The sand based mold includes a core part including grains of sand bonded with a resin, where a shape of the core part fits a shape of the cavity of the device, and a first pipe embedded into the core part and configured to allow a compressed fluid to flow through the first pipe during a solidification process of the device, the first pipe having an inlet and an outlet that exit the mold.

Abstract: The invention relates to microspheres coated with a phenolic novolak resin, a process for preparing them, and their use in making foundry shapes, e.g. molds, cores, sleeves, pouring cups, etc., which are used in casting metal parts.

Abstract: A method of making a wax mold for a golf club head includes the steps of: a) positioning a male die in a cavity of a female die; b) injecting and filling dissolvable wax into a gap between an outer surface of the male die and an inner surface of the female die; c) cooling and solidifying the dissolvable wax in the gap to obtain a wax shell; d) removing the wax shell from the male die and the female die, the wax shell being provided with a hole extending through inner and outer surfaces of the wax shell; and e) inserting a wax plug into the hole to form the wax mold.

Abstract: Molding sand having a high spherical degree and a low hygroscopicity produced from powder containing Al2O3 and SiO2, as main components by a flame fusion method, from which a mold having an excellent strength and a smooth surface is produced.

Abstract: A process for producing a metal article containing at least 10% interconnected porosity, using a preform (11), comprising: mixing an organic binder, a wetting agent and a granular material, to obtain a mouldable paste that combines 10 vol. pct. or more of said granular material, said material dissolving easily in a liquid solvent; shaping the paste into an aerated preform and providing an open pore space to be infiltrated by the metal or alloy; evaporating said wetting agent and baking said preform to a temperature sufficient to degrade the binder and create a network of interconnected open porosity in the preform; filling said open pore space with the liquid metal or alloy. All or part of the baked preform can be easily leached by a liquid solvent through the network of fine pores.