Abstract: A method of catching overflow of a liquid fluid utilized to cast a component is disclosed. Sand is compacted to form a mold. A cutter of a cutting device is in a disengaged position spaced from a top surface of the mold when the cutting device is in a first position and the cutter is in an engaged position engaging the top surface of the mold when the cutting device is in a second position. The cutter is actuated when the cutting device is in the second position and the cutter is in the engaged position to remove sand from the top surface to define a recess therein to catch overflow of the liquid fluid. The recess is spaced from an opening. At least one blocking mechanism, blowing mechanism and adjustment mechanism is utilized to assist the cutting device.

Abstract: An overflow system for casting a component is disclosed. The system includes a mold formed of sand. The mold includes a top surface that defines an opening for receiving a liquid fluid. A trenching assembly includes a cutting device movable relative to a frame between a first position and a second position. The cutting device includes a cutter that is in a disengaged position spaced from the top surface when the cutting device is in the first position and in an engaged position engaging the top surface when the cutting device is in the second position. The cutter defines a recess in the top surface when the cutter is in the engaged position. The recess is spaced from the opening for receiving excess liquid fluid. The trenching assembly further includes at least one of a blocking mechanism, a blowing mechanism and an adjustment mechanism that assists the cutting device.

Abstract: A method of catching overflow of a liquid fluid utilized to cast a component is disclosed. Sand is compacted to form a mold. A cutter of a cutting device is in a disengaged position spaced from a top surface of the mold when the cutting device is in a first position and the cutter is in an engaged position engaging the top surface of the mold when the cutting device is in a second position. The cutter is actuated when the cutting device is in the second position and the cutter is in the engaged position to remove sand from the top surface to define a recess therein to catch overflow of the liquid fluid. The recess is spaced from an opening. At least one blocking mechanism, blowing mechanism and adjustment mechanism is utilized to assist the cutting device.

Abstract: A method for machining a molding core from an aggregate material block, comprising: positioning the aggregate material block on a rotative base member; and rotating the base member and simultaneously machining the aggregate material block into the molding core. There is also provided a method for forming a casting mold including a molding core and a foundry casting core comprising: a core body having at least one convex shaped core print. The method comprises: providing at least one molding element having a mold cavity with at least one core-print pocket defined in a top side of the molding element; forming the molding core having at least one convex shaped core print; and inserting the molding core in the mold cavity with the at least one convex shaped core print engaged in a respective one of the at least one core-print pocket.

Abstract: A method for machining a sand molding element, comprising: inserting at least one hollow center body having an internal cavity in a predetermined position in a casting flask; filling the internal cavity of the hollow center body with unbonded sand; filling the casting flask with bonded sand to obtain a sand block; machining a mold cavity in the sand block; and emptying the internal cavity from the unbounded sand. There is also provided a method for machining a molding core from a sand block, comprising: providing a core base member having a concave upper surface; forming a sand block on the core base member with a lower surface of the sand block resting on the concave upper surface; and machining the molding core into the sand block, the molding core having a convex lower surface complementary to the concave upper surface of the core base member.

Abstract: A casting mold made of a copper material having a casting surface (2) that faces a metal melt, at least one expansion joint (3) being situated in the casting surface (2); the expansion joint (3) having a width (B) that is so small that, during the casting process, no metal melt penetrates into the expansion joint (3).

Abstract: A method for machining a sand molding element, comprising: inserting at least one hollow center body having an internal cavity in a predetermined position in a casting flask; filling the internal cavity of the hollow center body with unbonded sand; filling the casting flask with bonded sand to obtain a sand block; machining a mold cavity in the sand block; and emptying the internal cavity from the unbounded sand. There is also provided a method for machining a molding core from a sand block, comprising: providing a core base member having a concave upper surface; forming a sand block on the core base member with a lower surface of the sand block resting on the concave upper surface; and machining the molding core into the sand block, the molding core having a convex lower surface complementary to the concave upper surface of the core base member.

Abstract: A method for deburring a ceramic foundry core obtained by injecting a ceramic paste, the paste including a binder having a predetermined glass transition temperature, into a mold and having at least one surface portion with a surplus of material forming a burr to be eliminated. The method includes the following stages: a) disposing and attaching the molded, unfired foundry core onto a mounting; b) placing a milling tool, having an elongated shape with a helically cut edge, onto a tool holder; c) causing the tool to rotate around its axis and touching the milling tool to the surface portion to be deburred; and d) freezing the surface portion to be deburred such that the foundry core is maintained at a temperature lower than a glass transition temperature during the deburring operation.

Abstract: A digital processing method of a large or medium-size sand mold includes inverting a three-dimensional CAD model of a mold into a numeric controlling code, putting a prepared sand blank on a hollow grid-shaped processing platform to proceed the digital milling procedure, bringing away waste sand generated during processing by high pressure gas blown out from a nozzle near a cutter and the waste sand entering to a collecting device below the processing platform. A device for carrying out the method is disclosed. The method and the device reduce the processing steps.

Abstract: A mold boring apparatus including a mold boring tool having a flow passage formed inside of the mold boring tool which allows a fluid to flow therethrough, having slits and protruding portions formed on an outer peripheral portion of an outer body of a tool blade member of the mold boring tool in a circumferential direction thereof extending from a leading end to a base end of the tool blade member, and blades that are inclined inward and are formed at leading ends of the protruding portions formed between the adjacent slits.

Abstract: A method of making a turbomachine part, wherein the method can include machining a blank into a base having blades extending therefrom, the blades defining a channel therebetween. The method can also include forming a bridge constructed from refractory material in the channel between the blades, and forming a cover on the tops of the blades and over the channel, such that the base, the blades, and the cover form a single substantially homogenous turbomachine part once the bridge is removed.

Abstract: Compositions comprising (1) a refractory and/or a binder, and (2) bis-cyclopentadienyl iron cyclopentadienyl manganese tricarbonyl, derivatives thereof, and mixtures thereof.

Abstract: The invention relates to a method for producing a mould for casting metallic melts, in particular for casting titanium, titanium alloys or intermetallic titanium aluminides. Said method consists of the following steps: a contact layer is produced by applying a first slicker containing a first metal oxide powder as an essentially solid component to a moulded core, a first sanding layer is produced on the contact layer formed from the first slicker by sanding with a second metal oxide powder and the layer sequence formed from the contact layer and the first sanding layer is radiated with infrared light for a predetermined period of time. According to the invention, for speeding up the drying process, a first dry mass of the first slicker contains a hydraulic binder.

Abstract: Alloy products are produced with a waxless casting process. A model of a ceramic casting vessel (34) defining a desired product shape is digitally divided into sections (10, 40, 42). Each section is translated into a soft alloy mater tool (14) including precision inserts (20) where needed for fine detail. A flexible mold (24) is cast from each master tool, and a section of the ceramic casting vessel is cast from the respective flexible mold. The vessel sections are assembled by aligning cooperating precision features (58, 60) cast directly into each section and the alloy part is cast therein. No wax or wax pattern tooling is needed to produce the cast alloy product. Engineered surface features (54) may be included on both the interior and exterior surfaces of the shell sections.

Abstract: A method and master mold comprising a metal support layer and a fine structure pattern comprised of a glass or ceramic material, wherein the pattern support layer is formed of a first material having a relatively low grinding speed, and the fine structure pattern is formed of a layer of a second material having a grinding speed higher than that of the material of the pattern support layer.

Abstract: A method and apparatus are provided for total profile machining of a part, such as from a block of thermoplastic polymer. A first side of the part is machined together with an encircling recess. A registration/potting fixture is placed into the encircling recess. The registration/potting fixture is used to evacuate air from the machined side of the part and to pressure pack degassed fluid potting compound against the machined side of the part. The registration/potting fixture is cooled such as with a coolant to solidify the potting material. Then the registration/potting fixture is used to fixture the block in a new orientation for CNC machining another side of the part. Upon removal of the potting material from the part, the total profile machined part is freed for shipment to the customer.

Abstract: A method for producing a casting mold from a composite mold material for foundry purposes that is composed of different kinds of mold materials that are heat-resistant for the casting of metals and that differ in substantive composition or have different contents of organic or inorganic binders. A solid mold body is prepared from a foundry mold material A that is completely or partially encased during its preparation with a free-flowing chemically bonded foundry mold material B. A composite mold material block is formed after the hardening of the foundry mold material B, which is then machined by a cutting method such as milling, boring, turning, or grinding. The mold cavity is introduced into the mold body consisting of the foundry mold material A, and the inflow system and the feed system are introduced into the mold material block consisting of the foundry mold material B, using CAD data.

Abstract: Provide is a method for manufacturing a glass molding die in which deformation of a molding die in a process after machining is restrained without increased wear of a bit, and a method for manufacturing a molded glass article utilizing the glass molding die. A plated layer made of Ni—P plating is formed on the surface of a substrate, a rough machining is performed on the plated layer to form a shape similar to the desired final shape, the plated layer is then subjected to a thermal treatment, and finally finish machining is performed to form the desired final shape.

Abstract: A blade outer air seal (BOAS) casting core has first and second end portions and a plurality of legs. Of these legs, first legs each have: a proximal end joining the first end portion; a main body portion; and a free distal portion. Second legs each have: a proximal end joining the second end portion; a main body portion; and a free distal portion.

Abstract: A process for manufacturing a ceramic foundry core having at least one thin region with a thickness “e”, in particular in of a turbomachine blade trailing edge, including the forming in a mold of a mixture including a ceramic particle filler and an organic binder, the extraction of the core from the mold, the binder removal and consolidation heat treatment of the core. The process is one in which a core is formed in the mold, the region of this core being thickened relative to the thickness “e” by an overthickness E and in which the overthickness is machined after the core has been extracted from the mold and before or after the heat treatment operation. In particular, the machining is carried out mechanically by milling, either with removal of chips on the cores before firing, or by abrasion on the fired cores.

Abstract: A method of manufacturing a cast core with at least one recess, corresponding to a partition of a turbomachine blade, includes the steps of shaping, in a mold, a mixture containing a ceramic particles filler and an organic binder; forming a core rough casting without the recess in the mold; extracting the core rough casting from the mold; machining the recess in the core rough casting thereby forming a machined core with the recess; removing the organic binder from the machined core; and heat treating the machined core to consolidate the machined core. The step of machining the recess is performed before the step of heat treating the machined core.

Abstract: To manufacture a casting core, one or more recesses are formed in at least one face of metallic sheetstock. After the forming, a piece is cut from the metallic sheetstock. The piece is deformed to a non-flat configuration.

Abstract: A tire mold according to the invention includes a plurality of tread sectors for forming a tread portion of a tire and two shell inserts for molding the sidewalls of a tire wherein the tread sectors and the shell inserts are castings formed from the same model. A method for manufacturing a mold in accordance with the invention includes the steps of providing a casting model having the tread and sidewall features of a tire, the casting model having parting zones between the tread and sidewall, casting an element from the model, the cast element accordingly having parting zones between the tread and sidewall portions, and separating the cast element into a plurality of tread sectors and opposing sidewall shells.

Abstract: The invention relates to a method for producing heat-resistant casting molds from molding sand containing binder, particularly for producing an inner contour of casting molds for prototypes, large volumes and deep grooves often being produced especially in the machining of molds for rapid production of prototypes from casting materials. To increase efficiency, in a first step blocks of molding material are produced whose dimensions correspond to a mold cavity depth typically of 300 mm to 400 mm. The inner contour of the mold is then produced oversized with spacing close to the contour of the inner wall of the mold cavity by means of a roughing tool (4) that has an effective cutting diameter of 12 mm to 35 mm. The mold cavity is then machined by fast milling away of the oversize material following the contour, with a finishing cutter (3) that has a diameter-to-length ratio between 1:10 and 1:30.

Abstract: A method and an apparatus for machining a mold material to produce a mold. By casting based on a cast mold model (15), a mold material (20) is produced in a form having a work margin. Thereafter, a shape of the mold material (20) is measured by a measuring device (16), and measurement data and an envelope model (M2) generated based on the measurement data are stored in a storage unit (12A) of a computer (12). Thereafter, a mold model (M1) based on mold design data and an envelope model (M2) are displayed on a display unit (12C), and the envelope model (M2) is linearly moved in direction of three axes X, Y and Z orthogonal to one another respectively and rotated around the three axes to bring a product forming plane (M2B) of the envelope model (M2) into close proximity of a product forming plane (M1B) of the mold model (M1).

Abstract: A process for forming a mould or a core for casting molten metal by machining (e.g. cutting or drilling) to the desired shape a bonded particulate refractory material wherein the shear strength of the refractory particles is less than the shear strength of the bonds between the particles. The preferred particulate is aluminosilicate microspherers (e.g. “flyash floaters”) and the binder is preferably based on silica (e.g. fumed silica/sodium hydroxide). The bonded particulate material is easily machined to form accurately dimensioned moulds or parts thereof.

Abstract: The invention relates to a method for producing heat-resistant casting molds from molding sand containing binder, particularly for producing an inner contour of casting molds for prototypes, large volumes and deep grooves often being produced especially in the machining of molds for rapid production of prototypes from casting materials. To increase efficiency, in a first step blocks of molding material are produced whose dimensions correspond to a mold cavity depth typically of 300 mm to 400 mm. The inner contour of the mold is then produced oversized with spacing close to the contour of the inner wall of the mold cavity by means of a roughing tool (4) that has an effective cutting diameter of 12 mm to 35 mm. The mold cavity is then machined by fast milling away of the oversize material following the contour, with a finishing cutter (3) that has a diameter-to-length ratio between 1:10 and 1:30.

Abstract: This invention relates to a process for preparing detailed foundry shapes (e.g. molds and cores) used in casting metal articles. The process involves preparing foundry shapes from hollow ceramic microspheres bonded with organic or inorganic binders. The foundry shape is then detailed by machining, cutting, stamping, or otherwise removing material from the foundry shape to provide special shapes, letters, numbers, insignia, machine readable codes, etc. on the surface of the foundry shape. The foundry shapes are used to produce detailed metal castings. This detail can be unique to a single casting to provide a permanent traceable mark for casting identification from the time of manufacture to disposal.

Abstract: A tread pattern having at least one circumferential groove and transverse grooves extending from the circumferential groove defining tread blocks there between. The tread blocks include sidewalls limiting the longitudinal groove laterally and projections projecting from the sidewalls into the circumferential groove. The width of each of the projections is less than 10% the circumferential dimension of the respective tread block. To convert a mold having elements that produce tread blocks with substantially flat sidewalls into a mold that produces the tread pattern, channels are machines into the sidewalls of the mold elements.

Abstract: The invention is directed to a method for directly producing a lost mold by machining a sand mold made with curable binders. The invention is intended in particular to decrease tool wear and to increase dimensional accuracy and exactness in the reproduction of the mold, in that a mold blank (1) to be machined is constructed by means of a pattern set (4) with the use of a variable or fixed molding box (2) and includes in its volume the desired contours of the casting mold and a machining allowance for the milling of the mold material. After filling of the molding box (2) with curable foundry mold materials, curing, and removal from the mold, the mold blank (1) is transformed into the casting mold by removal of the machining allowance by high-speed machining, milling or 3-D machining of freeform surfaces. The invention concerns lost molds for metal castings and the fabrication of casting prototypes and odd parts in the range of small-and medium-sized articles and production runs.

Abstract: A method for machining a sand core, a cope, a drag or other molding element from a block of sand held together by binder material for use in foundry metal casting operations. The sand block is cut preferably with a diamond or carbide cutting bit of a computer numerical controlled (CNC) machine tool to cut a pattern into the sand block. A machine tool may be a mill, lathe, drill press, or other machine tool as appropriate. The sand block may be clamped in a variety of positions, and reference points are used to locate the sand block during each subsequent clamping and reclamping of the sand block to the various machine tools. The machined sand core is then inserted into a mold and used in foundry operations to create an internal cavity in a metal casting.

Abstract: A method for machining a sand core, a cope, a drag or other molding element from a block of sand held together by binder material for use in foundry metal casting operations. The sand block is cut preferably with a diamond or carbide cutting bit of a computer numerical controlled (CNC) machine tool to cut a pattern into the sand block. A machine tool may be a mill, lathe, drill press, or other machine tool as appropriate. The sand block may be clamped in a variety of positions, and reference points are used to locate the sand block during each subsequent clamping and reclamping of the sand block to the various machine tools. The machined sand core is then inserted into a mold and used in foundry operations to create an internal cavity in a metal casting.

Abstract: A method for machining a sand core, a cope, a drag or other molding element from a block of sand held together by binder material for use in foundry metal casting operations. The sand block is cut preferably with a diamond or carbide cutting bit of a computer numerical controlled (CNC) machine tool to cut a pattern into the sand block. A machine tool may be a mill, lathe, drill press, or other machine tool as appropriate. The sand block may be clamped in a variety of positions, and reference points are used to locate the sand block during each subsequent clamping and reclamping of the sand block to the various machine tools. The machined sand core is then inserted into a mold and used in foundry operations to create an internal cavity in a metal casting.

Abstract: A grid casting mold for the casting of accumulator lead grids has two plates (11, 12) which can be placed against one another with a casting profile (13) or mold cavity complementary to the lead grid which is to be manufactured being formed in their confronting mold surfaces. The plates (11, 12) moreover have a base body (14, 15) which is provided at the profile side with a thermally insulating layer (16, 17) of high temperature fiber ceramic material which is coated on the side remote from the base body (14, 15) with a high wear resistant metal oxide (18, 19).

Abstract: In connection with a device for casting lead grids for electric battery plates, a highly porous ceramic mold lining, preferably of zirconium oxide, is prepared by flame-spraying. Such a lining can include a thin surface coating on a profiled, basic metallic mold or a separately prepared insert plate which is retained to a metallic mold molder. The ceramic surface coating may be accurately formed in place, or may be formed as an over-spray which is then reduced in thickess. Formation of the surface coating may be accomplished by placing masks on the basic metallic mold during the flame spraying, for those areas of the grid which tend to accumulate material, or by adjusting an initially coarse profile of the ceramic layer to the exact profile of the casting by a material-removing treatment.

Abstract: A drag bit with a faceted profile and method of its manufacture by which the facets provide for planar mold surfaces upon which cores having planar ends can completely contact the surface of the mold. The invention is particularly though not exclusively adapted to matrix body drag bits incorporating PDC cutters having tungsten carbide studs or cylinders which are mounted in wings, ribs or blades of the bit body. In accordance with a preferred embodiment of the present invention, the wings, ribs or blades have a small planar surface or facet at each PDC cutter location with each of the facets being at a consistent angular disposition with respect to the axis of the corresponding cutter stud. The facets are created by flat mold surfaces which facilitate the proper positioning and angular disposition of the cores which form the openings in the matrix for receiving the PDC cutters.

Abstract: Tubular metal articles are produced by centrifugal casting in a rotary metal mold lined by centrifugally distributing a quantity of a dry finely particulate free flowing refractory material on the active mold surface with the quantity being in excess of that required for the lining, densifying the layer by rotating the mold at a rate such that the refractory layer is subjected to centrifugal force adequate to establish an equivalent specific gravity of at least 7.5, determined by multiplying the actual specific gravity of the refractory material by the number of gravities of centrifugal force, contouring the densified layer and removing the excess refractory material, rotating the mold at the casting rate and then introducing the molten metal for casting while continuing to rotate the mold at least that rate. Articles so cast have relatively smooth outer surfaces which require only finish machining.

Abstract: A method of making a mold by the use of sand is started by filling a mass of sand in a mold jacket which is in turn rammed to provide a block of sand. The sand block thus formed is excavated by a cutting device to form a mold cavity. The cutting device is guided by a profiling machine in accordance with a predetermined program which describes the shape of an ultimately desired casting to be manufactured by the use of the sand mold.

Abstract: A segmented mold assembly is utilized to cast a turbine engine component having an annular inner wall and an annular outer wall which are interconnected by a plurality of struts or vanes. The mold assembly includes a plurality of sections which are formed of a ceramic mold material and are interconnected at flange joints. A pair of mold sections are advantageously formed simultaneously by repetitively dipping a single pattern in a slurry of liquid ceramic mold material to form a wet coating on the pattern. This wet coating of ceramic mold material is then dried. After a covering of the desired thickness has been built up by repetitively dipping and drying the coatings on the wax pattern, the wax pattern is destroyed. To facilitate separating the mold sections after destroying the wax pattern, at least some of the wet coatings are wiped away in an area between portions of the wet coatings which will eventually form the mold sections.

Abstract: An improved method of forming a shell mold for casting having a shrink bob is provided. A tubular frusto-conical shrink bob, or riser, is first formed from sand and a plastic or resin binder such that both the apex and base of the riser are open. The riser is then inverted and positioned on a casting pattern with the apex of the riser abutting against the casting pattern. The entire pattern is then cast with a thermosetting material, such as sand and a binder, such that the thermosetting material bonds to both the pattern and the riser. After hardening, the thermosetting material with the attached riser forms a shell mold which is subsequently utilized in a foundry casting operation.

Abstract: A method of making investment shell molds by the lost pattern process characterized in that a strand such as wire or the like is wound circumferentially about a pattern assembly in at least one location before it is coated with refractory material to form a mold shell. Thereafter, the strand is unwound to separate the shell into segments, each of which is usable as a mold.

Abstract: A method for producing sculptures which have a thin-walled outer metal shell and an internal soft core made of plaster, for example. A mold of the sculpture to be fabricated is constructed smaller by the thickness of the metallic outer shell. A substance which can withstand high temperatures when coming into contact with molten metal, such as plaster, is then poured into the mold. After the plaster cast is removed from the mold, a layer of wax is applied with a thickness exceeding the thickness of the final metallic shell. The final shape of the sculpture is then cut on the exterior surface of the wax, so that the wax layer has a thickness corresponding to the thickness of the outer metallic shell. The cut wax layer is then covered with plaster, and heat is applied to melt the wax and allow the wax to drip out through an opening in the outer plaster layer.

Abstract: Tubular metal articles are produced by centrifugal casting in a rotary metal mold lined by centrifugally distributing a quantity of a dry finely particulate free flowing refractory material on the active mold surface with the quantity being in excess of that required for the lining, densifying the layer by rotating the mold at a rate such that the refractory layer is subjected to centrifugal force adequate to establish an equivalent specific gravity of at least 7.5, determined by multiplying the actual specific gravity of the refractory material by the number of gravities of centrifugal force, contouring the densified layer and removing the excess refractory material, rotating the mold at the casting rate and then introducing the molten metal for casting while continuing to rotate the mold at least that rate. Articles so cast have relatively smooth outer surfaces which require only finish machining.