Abstract: A method and casting core for forming a landing for welding a baffle inserted into an airfoil are disclosed, wherein the baffle landing of the blade or vane is formed in investment casting by the casting core rather than by wax, reducing tolerances and variability in the location of the baffle inserted into the cooling cavity of airfoil when the baffle is welded to the baffle landing.

Abstract: A core shooting machine (1) for producing cores by a process of shooting a core sand mixture (21) into at least one cavity (19) in a core box (18), the core shooting machine (1) having a source of compressed air (10) at an adjustable initial machine pressure (P0), a shooting head (13) fluidically coupled to the source of compressed air (10) by at least one conduit (12) that includes an electronically controlled shot valve (11), the shooting head (13) being configured for containing an amount of the core sand mixture (21), resulting in a filling degree of the shooting head (13), and a computing device (50,60) associated with the core shooting machine (1) and being configured to perform a simulation of the process.

Abstract: A method for forming a metallic structure having multiple layers includes providing a main tool having a main formation surface corresponding to a desired shape of a first layer of material. The method also includes depositing the first layer of material on the main formation surface using a cold-spray deposition technique. The method also includes positioning a secondary tool having a secondary formation surface in a portion of a first volume defined by a first surface of the first layer of material. The method also includes depositing a second layer of material on the secondary formation surface using the cold-spray deposition technique. The method also includes removing the secondary tool such that the first volume is positioned between the first layer of material and the second layer of material.

Abstract: “Lost” cores for use high pressure die casting, the cores preferably having a water-soluble synthetic ceramic aggregate having an appropriate strength and tolerance for various casting pressures and temperatures, an inorganic binder having sodium silicate, an additive having particulate amorphous silicon dioxide, and a refractory coating, wherein the cores have the capacity to be removed from a casting by dissolution with water.

Abstract: A pattern forming method includes: preparing a pattern paper comprising a fiber where a pattern to be formed is formed; impregnating the pattern paper with a releasing agent; and forming the pattern on a pattern forming target by arranging the pattern paper on a mold comprising an upper mold and a lower mold, and adhering the pattern paper to the pattern forming target by using the mold.

Abstract: A tool for forming a shaped product has a support body that is fabricated from a first material, such as for instance cast iron. The first material defines a first portion of a forming surface of the tool and has a feature supported thereon. The feature has a layer of a second material that is supported on the first material of the support body, a layer of a third material that is supported on the layer of the second material and a layer of a fourth material that is supported on the layer of the third material. The layer of the fourth material, such as for instance a tool steel alloy, defines a second portion of the forming surface of the tool. During use the first portion of the forming surface and the second portion of the forming surface cooperate to form a desired shape of the shaped product.

Abstract: A mold assembly for use in forming a component having an outer wall of a predetermined thickness is provided. The mold assembly includes a mold that includes an interior wall that defines a mold cavity within the mold. The mold assembly also includes a jacketed core positioned with respect to the mold. The jacketed core includes a jacket that includes an outer wall. The jacketed core also includes a core positioned interiorly of the jacket outer wall. The jacket separates a perimeter of the core from the mold interior wall by the predetermined thickness, such that the outer wall is formable between the perimeter and the interior wall.

Abstract: A mold assembly for use in forming a component having an outer wall of a predetermined thickness includes a mold and a jacketed core. The jacketed core includes a jacket that includes a first jacket outer wall coupled against an interior wall of the mold, a second jacket outer wall positioned interiorly from the first jacket outer wall, and at least one jacketed cavity defined therebetween. The at least one jacketed cavity is configured to receive a molten component material therein. The jacketed core also includes a core positioned interiorly from the second jacket outer wall. The core includes a perimeter coupled against the second jacket outer wall. The jacket separates the perimeter from the interior wall by the predetermined thickness, such that the outer wall is formable between the perimeter and the interior wall.

Abstract: The core sand filling device includes the core box, a blow head which is placed below the core box so as to move up and down in a relative manner to the core box and divided into a sand blowing chamber and a sand storage chamber that are communicatively connected to each other, a compressed air supply unit which is communicatively connected to the sand storage chamber and supplies compressed air into the sand storage chamber, an aeration air supply unit which is communicatively connected to the sand blowing chamber and supplies into the sand blowing chamber aeration air for suspending and fluidizing core sand inside the sand blowing chamber, and an exhaust valve which is communicatively connected to the sand blowing chamber and exhausts compressed air remaining in the sand blowing chamber.

Abstract: A method of producing an integral self supporting coating test piece from particulate material including the steps of (i) producing a reusable mould having a depression which conforms to the desired shape and volume of said coating test piece, the reusable mould including silicone rubber, (ii) roughening the surface of the reusable mould, (iii) heat treating the reusable mould, (iv) thermally spraying particulate material into the depression in the reusable, mould, and (v) removing the reusable mould from the solidified coating test piece.

Abstract: A molding machine which allows a simplification of a sand filling operation, and the prevention of the formation of a bridge and an air channel in the sand tank, so that the sand filling operation of the molding machine is able to be performed steadily. The molding machine of the present invention includes: a sand tank for storing molding sand to be introduced to a molding flask; a pair of upper and lower sand filling nozzles to guide the molding sand in a horizontal direction, where the molding sand is supplied from a pair of upper and lower sand introducing parts which are located at the lower part of the sand tank; and at least one filter part with a plurality of air-injecting apertures on its entire body, which is attached to at least the entire inner surfaces of the pair of sand introducing parts; wherein the molding sand is fluidized by air injected through the air-injecting apertures of the filter part, and introduced to the molding flask through the sand filling nozzles.

Abstract: The present invention provides a technique capable of decreasing a generation of splashing upon depositing by using an Al—Ni—La—Cu alloy sputtering target comprising Ni, La, and Cu. The invention relates to an Al—Ni—La—Cu alloy sputtering target comprising Ni, La and Cu, in which (1) a total area of an Al—Ni intermetallic compound mainly comprising Al and Ni and having an average grain size of 0.3 ?m or more and 3 ?m or less is 70% or more by area ratio based on an entire area of the Al—Ni intermetallic compound, and (2) a total area of an Al—La—Cu intermetallic compound mainly comprising Al, La and Cu and having an average grain size of 0.2 ?m or more and 2 ?m or less is 70% or more by area ratio based on an entire area of the Al—La—Cu intermetallic compound, in a case where a portion of the sputtering target is observed within a range of from ¼t (t: thickness) to ¾t along a cross section vertical to a plane of the sputtering target by using a scanning electron microscope at a magnification of 2000.

Abstract: The present invention is to provide a machine and a method for suctioning and exhausting air from a storage tank for sand in a molding machine that has less on-off valves and prevents sand from adhering to the interior of the valve for exhausting air while the air is being exhausted.

Abstract: This invention provides a mold for injection molding and a method of manufacturing thereof. The method of manufacturing a mold for injection molding includes the following steps. At least one temperature control element is provided. The temperature control element is covered with a first material. The first material is mechanically processed to form a mold body with a cavity. The mold for injection molding includes a mold body, a temperature control element, and a heat insulating layer.

Abstract: A hybrid ceramic/sand casting method of manufacturing a metal part. The method is especially suitable for parts having one or more very small internal gaps, such as might occur with a linear passage or round opening. These parts are formed using a hybrid core having at least one ceramic section and at least one sand section, with the ceramic section being used to create the internal gap. A mold cavity is created for the part, and the hybrid core is positioned in the mold. Molten metal is introduced into the mold, and after the metal cools, the core is removed, thereby forming the part with the internal gap.

Abstract: A method for manufacturing a mold, including steps of (a) expanding a powder mixture containing a water-soluble inorganic salt powder and a water-soluble organic polymer powder in a plane on a table and then selectively spraying a spray liquid containing at least one selected from a water-miscible organic solvent and water through a nozzle on this powder mixture layer to make a bonding strength among particles of the powder mixture in a sprayed region higher than that among particles of the powder mixture in an unsprayed region, (b) further expanding the powder mixture on the powder mixture layer after spraying and then selectively spraying the spray liquid through the nozzle on this powder mixture layer, (c) repeatedly conducting the step (b) over several times to form a mold shaped by the sprayed regions, and (d) taking out the mold.

Abstract: To produce moulds or cores for foundry purposes from a mixture (M) of moulding material or sand and a binder, the mixture (M) is shot using a shooting unit (2) or from a shooting tube (3) and a shooting head (4) through at least one discharge opening (7) arranged on a shooting plate (5) into a moulding or core tool (8). The region of the discharge opening (7) is moistened and/or kept moist by a liquid between at least two shooting operations, where the liquid (15) used for moistening is atomized by at least one ultrasonic atomizer (16) to form an aerosol capable of suspension and is fed to the discharge opening (7) directly or indirectly, for example, via one or more lines (18, 23).

Abstract: Procedure for the production of sleeves for mini-deadheads and an economical method of casting incorporating the use of said sleeves. A fluoride-free mixture, consisting of microspheres of aluminium silicate, an oxidizable metal, such as powdered aluminium, an oxidizable agent, magnesium as initiator element of the exothermic reaction, are introduced by blowing in a mould fitted with two cores to produce a sleeve provided with two openings, one of which is closed with a plug before being used.

Abstract: A metallic shell used, for example as a mold, is formed by spray deposition of metallic layers over non-metallic layers as, for example, a reinforcing fabric.

Abstract: A method and automated matchplate molding machine for blowing sand horizontally into the horizontally spaced open ends of the cope and drag flasks with a perpendicular trajectory relative to a vertically aligned matchplate between the cope and drag flasks. Sand is pneumatically blown horizontally from sand magazines through opposing ends of the cope and drag flasks toward the matchplate. The cope and drag flask can be turned between upright and rotated positions. The machine disassembles the mold flask and removes the mold in the upright position and fills the mold with sand horizontally when in the rotated position. The molding machine includes a rotating turret that carries two mold flasks between a mold forming station and a draw station. The mold flasks may also be rotated about a horizontal axis relative to the turret to facilitate turning of the mold flasks between upright and rotated positions.

Abstract: A method and automated matchplate molding machine for blowing sand horizontally into the horizontally spaced open ends of the cope and drag flasks with a perpendicular trajectory relative to a vertically aligned matchplate between the cope and drag flasks. Sand is pneumatically blown horizontally from sand magazines through opposing ends of the cope and drag flasks toward the matchplate. The cope and drag flask can be turned between upright and rotated positions. The machine disassembles the mold flask and removes the mold in the upright position and fills the mold with sand horizontally when in the rotated position. The molding machine includes a rotating turret that carries two mold flasks between a mold forming station and a draw station. The mold flasks may also be rotated about a horizontal axis relative to the turret to facilitate turning of the mold flasks between upright and rotated positions.

Abstract: A facsimile of article to be produced by tooling is laid in register with a first tooling part and sprayed metallic material is deposited over the first tooling part and the facsimile of the article in order to form a second tooling part. The first tooling part typically comprises a metallic material and portions of the first and second tooling parts bounding the article facsimile are typically in metal to metal contact with one another. The tooling parts are separated and the article facsimile removed.

Abstract: A method of making a spray formed rapid tool includes the steps of making a model of a desired tool and constructing a ceramic pattern as the inverse of the model. The method also includes the steps of heating the ceramic pattern and thermally spraying a metal material against the ceramic pattern to form a desired tool.

Abstract: A metallic shell used, for example as a mold, is formed by spray deposition connected to a base by rods or other supports connected to mounting elements which are incorporated in the shell during the deposition process. The shell can incorporate different metals to provide different thermal conductivity in various regions.

Abstract: The method comprises the production of a first positive model of an item to be cast. The positive model is produced with a flange extending in an imaginary separation line of the item. The flange extends both inwardly in the item within an outer periphery of the item and outwardly outside the outer periphery of the item. The flange establishes an artificial increase of the thickness of the item. Through different intermediate steps at least a first mould part and a second mould part of a mould are produced. The first and the second mould part of the mould initially have a separation zone forming a contact surface between the first and the second mould part. The mould parts are treated in the separation zone so that the negative moulds of an upper and a lower surface of the part of the flange extending outside the item will subsequently form a contact surface of the first and the second mould part.

Abstract: A spray forming pattern of a first metal having a melting point at a first temperature is formed. The spray forming pattern has a surface defining a cavity that has the shape of a master pattern. Steel particles having a carbon content in the range of 0.01-0.9% by weight are sprayed onto the spray forming pattern to form a deposit on the spray forming pattern. The deposit has a thickness of at least 0.5 inches and the temperature of the steel particles increases as the thickness of the steel deposit increases. The spraying conditions are controlled so that the steel particles coming into contact with the spray forming pattern results in a surface temperature of the spray forming pattern of less than about 80.degree. C. The deposit and the spray forming pattern are heated to a second temperature, which is higher than the first temperature, to melt the spray forming pattern from the deposit. The resulting deposit has the general shape of the master pattern.

Abstract: A system for the spray forming manufacturing of near-net-shape molds, dies and related toolings, wherein liquid material such as molten metal, metallic alloys, or polymers are atomized into fine droplets by a high temperature, high velocity gas and deposited onto a pattern. Quenching of the atomized droplets provides a heat sink, thereby allowing undercooled and partially solidified droplets to be formed in-flight. Composites can be formed by combining the atomized droplets with solid particles such as powders, whiskers or fibers.

Abstract: Metallic articles having heat transfer channels are produced by solidification of molten metallic material about pre-formed channel defining members such that a solidified metallic deposit having heat transfer channels is formed. The channel defining members may be in the form of either solid elements (which are subsequently removed to leave the channels), or conduit elements (which may remain permanently embedded in the article). Moulds, dies, cores and other tools for use in moulding or casting of plastics and metals are particularly suitably formed by the process, the heat transfer channels being used for cooling of the respective articles during use. The molten metallic material is preferably deposited by spray forming utilizing one or more sprays of molten metallic material.

Abstract: A method for spray forming manufacturing of near-net-shape molds, dies and related toolings, wherein liquid material such as molten metal, metallic alloys, or polymers are atomized into fine droplets by a high temperature, high velocity gas and deposited onto a pattern. Quenching of the atomized droplets provides a heat sink, thereby allowing undercooled and partially solidified droplets to be formed in-flight. Composites can be formed by combining the atomized droplets with solid particles such as whiskers or fibers.

Abstract: A method for forming a replica stamper for use in mass producing an optical disk, wherein the optical disk has a plurality of tracks arranged spirally or concentrically, and each of the tracks includes a recess and a protrusion for recording information signals thereon, comprises the steps of: (a) preparing a master stamper having a top surface and a flat bottom surface, wherein the top surface of the master stamper includes a plurality of tracks corresponding to the plurality of tracks of the optical disk; (b) depositing a buffer layer on the top surface of the master stamper; (c) forming a replica stamper on top of the buffer layer; (d) disengaging the master stamper from the buffer layer and the replica stamper; and (e) removing the buffer layer from the replica stamper.

Abstract: An apparatus for cleaning shot hoods during the manufacture of casting molds or core packets that are ready for casting, by means of core shooters or shooting stations, preferably in a linear arrangement, the core shooters in each instance incorporating a shot hood (3) that comprises a shot plate (1) and shot nozzles (2), it being possible to uncouple the shot hood (3) from the core shooter and lay it on a pallet (4) or the like with the shot nozzles (2) pointing downward, characterized by a delivery system (5), a transfer station (6), an emptying station (7), a flushing system (8), a drying system (9), an exit station (10), optionally an inspection station, and a removal system (11), the shot hood (3) that has been laid upon the pallet (4) being moveable from the core shooter to the transfer station (6) by means of the delivery system (5), it then being possible to raise it from the pallet (4) by means of a first manipulator (12) and pivot it through approximately 180.degree.

Abstract: Making a tire mold by spraying molten atomized metal on a model to form a metal shell and then reinforcing the shell with a resin backing to form a mold segment for the tire mold. Modular shoe container assemblies have replaceable backing members for making different size molds and flat plate spacers for providing different thicknesses of the mold segment. In one embodiment a slide block is used for one side of the cavity whereby a sole plate is eliminated.

Abstract: Tools and dies are made from a master pattern by making a hard chromium electroformed shell from the pattern, supporting the pattern and filling it with tool steel which applied by spray deposition of molten particles, the deposit being continuously densified by peening as it is made.

Abstract: Ballistic armor is fabricated by spraying atomized particles of molten ballistic armor metal alloy onto a collector utilizing a pressurized inert gas which impacts upon a controlled feed of the molten armor metal alloy. Dual hardness armor plate and parts are produced by spraying a second layer of a different armor metal alloy onto the first layer either before the first layer has completely solidified or while a semi-liquid surface exists on the first layer.

Abstract: A method for rapid tool manufacturing comprising the steps of first building an SFF pattern made of plastic to be used to make a first die half. Then there is the step of spraying metal onto the pattern to form a first metal substrate. Next, there is the step of separating the substrate from the SFF pattern to form the first die half. Then there is the step of building a second SFF pattern to be used to make a second die half. Next, there is the step of spraying metal onto the second SFF pattern to form a second metal substrate. Then there is the step of separating the second metal substrate from the second SFF pattern to form the second die half. In a preferred embodiment, the method for rapid tool manufacturing the second die half is formed by first the step of building an SFF model of a part to be molded. Then, there is the step of inserting the model into the first die half. Next, there is the step of spraying metal onto the model in the first die half to form a second metal substrate.

Abstract: In a process for producing mouldings, into whose interior is introduced a medium, particularly for producing core boxes for core shooting, in the mould cavity are provided ventilating holes or vents which are occupied by nozzles. During the moulding of the moulded part or a core member arranged therein, particularly the core box, at least one insert is inserted, whose shape corresponds to that of the nozzle. After the moulding of the core box the insert is removed and replaced by the nozzle.

Abstract: A foundry machine for forming molds or cores from a molding material such as sand provides completely automated loading and unloading of tooling elements (24). The tool elements (24) comprising a sand magazine (36), blow plate (34), combined gassing manifold and top ejector unit (32), upper mold box (30), lower mold box (28) and bottom stool (26) are automatically transferred, in stacked, separable relationship, by tracks (40) to a vertically displaceable, work table. Vertical displacement of the work table (42) sequentially elevates the tooling elements (24) to positions within a mainframe (10) where automatically operated clamping means secure the appropriate tooling elements (24) in respective operating positions. The gassing manifold (32) includes an ejector pin assembly (274, 280) mounted therewithin.

Abstract: High melting point metallic, e.g., steel mold members are facilely and inexpensively produced by depositing, e.g., flame-spraying, droplets of a melt of a metal having a high melting point onto the front face surface of an elastomeric silicone mold pattern, said elastomeric silicone containing from 20 to 90% by weight of finely divided particulates of at least one refractory filler, and thereafter permitting said melt to solidify.

Abstract: An apparatus and method for making cores from green sand continuously and automatically. The method comprises blowing the green sand together with compressed air into a die cavity formed by a pair of dies, stabbing the green sand filled in the die cavity by stabbing rods to compact the green sand thereby to form a core, and applying a surface stabilizing agent to the surface of the core taken out from the dies, followed by drying of the core. Disclosed also is an apparatus suitable for carrying out this method.

Abstract: A foundry molding-apparatus and method with at least one sand delivery device in communication with a mold chamber having at least one sand inlet opening and air exit opening, and provided by a mold box, a sand frame, at least one pattern plate carrying the mold box, and at least one mold head which is mounted at the apparatus, axially spaced from the pattern plate, and includes a perforated press plate. With respect to the pattern plate, the sand frame and the sand delivery device are together vertically adjustably movable with respect to the pattern plate and guided by a guide means mounted about the apparatus relative to the central longitudinal axis of the apparatus. The opening of the sand delivery device extends transversely to the longitudinal central axis of the apparatus. The passage leading to the mold chamber extends at an angle to the central longitudinal axis of the apparatus.

Abstract: A method of manufacturing a mold adapted to be used for casting bodies of fiber-reinforced composites. A model of the body to be cast is prepared and coated with a one-piece dense shell of refractory metallic oxide deposited by plasma or flame spraying and the model is then separated from the shell by conventional physical or chemical treatment.

Abstract: A method of manufacturing a mold adapted to be used for casting bodies of ber-reinforced composites. A model of the body to be cast is prepared and coated with a one piece dense shell of refractory metallic oxide deposited by plasma or flame spraying and the model is then separated from the shell by conventional physical or chemical treatment.

Abstract: A chill preventing arrangement is used in a metal mold employed in centrifugal casting. The metal mold is provided, at its spigot portion, with an end plate which has a central opening smaller in diameter than the internal diameter of the metal mold main body and which includes a metallic base plate, an intermediate layer of metallic alloy formed by flame or plasma spraying on a surface of the metallic base plate contacting the molten metal for casting, and a coating of ceramic material more than 0.7 mm thick formed on the intermediate layer by flame or plasma spraying for preventing chill formation at the corresponding end portions of tubular castings.

Abstract: A belt-type metal-casting machine comprises a metallic casting belt, preferably of steel, having its side turned toward the melt formed with a heat-lagging (thermal-insulating) layer upon which at least one abrasion-resistant cover layer is applied. The cover layer consists of one or more metals whose fusion temperature or melting point in Kelvin .degree. is equal to or greater than 0.7 times the melting temperature, in .degree.K, of the casting metal to be applied.