Abstract: A mold for manufacturing a wind turbine blade, including: a lower mold component, and an upper mold component, wherein the lower mold component and the upper mold component form a mold cavity in the shape of a wind turbine blade, and the upper mold component includes at least two upper mold parts is provided. The required floor-to-ceiling height of a production hall is decreased and the required lifting capacity of a crane is lowered.

Abstract: Aspects of the disclosure are directed to treating a substrate, the substrate including at least one of a refractory metal or a ceramic material, and depositing a media onto the treated substrate to generate a casting core. Embodiments include a fixture, a substrate located on the fixture, the substrate including at least one of a refractory metal or a ceramic material, and a delivery head that deposits media onto the substrate to generate a casting core. Aspects are directed to a core configured for casting a component, the core comprising: a substrate that includes at least one of a refractory metal or a ceramic material, and media deposited on the substrate, the media having a dimension within a range of between 0.5 and 500 micrometers.

Abstract: A mold insert assembly includes a base section having a base side removably attachable to a base plate of a mold and a first interface surface having a notched portion thereon. A first section includes a first interface side with a first interconnecting tab sized to engage the notched portion of the base section when the first interface side abuts the first interface surface, the first section further including an adjoining side having an interconnecting notch. A second section includes a second interface side having a second interconnecting tab, where the second interconnecting tab is sized to engage the interconnecting notch of the first section when the second interface side abuts the adjoining side, and where the base section, the first section, and the second section when assembled form a contoured insert configured to create a contoured cavity in a part formed within the mold.

Abstract: A molding apparatus is provided. The molding apparatus includes a first block configured to receive a moldable article therein, a second block positioned a distance from the first block, and a shim including graphite. The shim is positioned between the first block and the second block, wherein the shim gradually disintegrates when heated such that the second block contacts the first block.

Abstract: A composite core for forming a passage in an investment casting mold is provided including a generally hollow structural element. The structural element is configured to deform when a force is applied to an end thereof. A rigid shell element is formed about the structural element. The shell element extends beyond both an interior surface and an exterior surface of the structural element. The shell element is configured to shatter when the structural element deforms.

Abstract: An injection mold producing a model of a turbine engine blade, including: a top surface that folds onto a bottom surface, both surfaces including long rods for supporting a core generating cooling cavities inside the blade, wherein the long rods of the bottom surface are configured to contact a first surface of the airfoil at bearing points, and the long rods of the top surface are configured to contact a second surface of the airfoil at clamping points; at least one short rod extending from one of the surfaces of the mold and pointing towards a false point located on one of the surfaces of the airfoil, the length of the short rod being shorter than the distance between the surface of the mold and the surface of the blade at the false point, and the difference between the length and the distance being equal to tolerance in relation to positioning of the false point in event of deformation of the core.

Abstract: An apparatus and method for molding a freight car yoke with a one piece core is disclosed herein. An exemplary one piece core may be used with a core mold upper half and a core mold lower half mated at a common split line to define a mold cavity which replicates the molded exterior features of a freight car yoke. The one piece core may replicate all of the molded internal features of a freight car yoke. An apparatus may use a pair of one piece cores to produce a pair of freight car yokes. An exemplary method can utilize the apparatus to produce a pair of freight car yokes through a single pour, using a pair of one piece cores. In an exemplary embodiment the one piece cores are constructed from a cold box with phenolic urethane treated molding sand.

Abstract: The present invention concerns equipment (1) for making foundry cores comprising a mold (2) provided with one or more core forms (3) and one or more channels (4, 6, 7) for conveying core formation material to the core forms (3). The equipment comprises one or more inserts (10) housed or able to be housed in the conveying channels (4, 6, 7) near to the core forms (3).

Abstract: A main body core box assembly for creating coupler head cores which are attachable to various shank cores includes a main body core box including two halves, each half including a pattern configured to form the outer walls of a first head core having a first shank core. A plug is insertable into an end of respective patterns to form a second, alternative head core having a first half of a connection joint attachable to a second shank core that includes a second half of the connection joint, the second shank core being different than the first shank core. The first half of the connection joint may be a male connector, where the plug includes a recess having an angled surface to create a notch on the male connector. The second half of the connection joint may be a female connector with a raised surface corresponding to the notch.

Abstract: A system for creating an interlock feature between two related railcar coupler cores comprises a first half of a corebox defining cavity for forming a first half of a railcar coupler core, a second half of a corebox defining a cavity for forming second half of a railcar coupler core, and a loose piece loose piece including an extension on a first side shaped to fit in the cavities.

Abstract: The present invention concerns equipment (1) for making foundry cores comprising a mould (2) provided with one or more core forms (3) and one or more channels (4, 6, 7) for conveying core formation material to the core forms (3). The equipment comprises one or more inserts (10) housed or able to be housed in the conveying channels (4, 6, 7) near to the core forms (3).

Abstract: A one-piece core-making technique used in producing railway truck bolsters and side frames, which includes the following steps: 1. After scraping the top of a core box, applying a shaped top mould (11), which is precisely located, from top to bottom. 2. Press or slightly hit the top mould (11) to make sure the top mould covers/caps the scraping surface. 3. Keep pressing to make sure that the flat scraping surface was pressed to a required curved shape, like the shape of the top mould (11). 4. Last, it will become a one-piece core with a partially integrated inner cavity section. The one-piece core made by this technique has a smooth surface. This technique also can improve the internal quality of the product and ease work intensity.

Abstract: A ceramic core is produced by introducing a fluid ceramic core material, such as a ceramic slurry, into a core-shaped cavity formed at least in part by one or more fugitive core tooling liners residing in a back-up body, removing the ceramic core from the cavity, and removing the one or more fugitive tooling liners from the back-up die body and discarding them. The fugitive tooling liners and optional tooling inserts are used in one or more production cycles (e.g. ceramic slurry injection cycle) to make a single or multiple ceramic cores and then replaced with fresh (un-used) tooling liners and optional inserts to make other ceramic cores.

Abstract: A tool for manufacturing a casting core, for a turbomachine blade with a leading edge and a trailing edge, the core includes a thick part on the leading edge side and a thin part on the trailing edge side is disclosed. The tool includes first and second dies of the core that are moveable in a direction with respect to each other between a molding position and a demolding position, sub-components that are moveable relative to the dies, and mechanical ejectors that are provided on the first and second dies. The parts of the dies corresponding to the thin part of the core do not include a movable sub-component. The thin part of the core is demolded along the main direction of opening of the first and second dies.

Abstract: A process for producing a mold includes introducing a composition including a particulate, refractory material and a binder into a hollow model having an interior cavity which determines contours of all surfaces of the mold or a mold part, wherein the model includes at least two separate parts to permit removal of the mold, and applying a second composition containing at least one organosilicon component and at least one solvent to at least one of the separable parts before use.

Abstract: The invention relates to a casting tool for the production of castings, particularly cores for sand castings, pressure die-castings, and gravity diecastings, comprising a first casting tool unit (2) including a first casting mold half (22) having a first mold recess (24) the contour (22b) of which at least partly defines the shape of the casting, an ejecting assembly (6) disposed on that side of the first casting mold half (22) which faces away from the first mold recess (24) and capable of movement in the direction of a Z-axis relatively to the first casting tool unit (2) and having at least one ejecting rod (62) which can extend through an access bore (22a) into the first mold recess (24) in the first casting mold half (22), wherein an entrainer unit (76) is attached to the ejecting assembly (6), to which entrainer a contact surface (30a) provided on the first casting tool unit (2) is assigned for contacting the entrainer (76), wherein the entrainer (76) and the contact surface (30a) jointly define the maxi

Abstract: The invention relates to a casting tool for the production of castings, particularly for the production of cores (90) for sand castings, comprising a supporting device consisting of a first and a second supporting unit (10, 20, 50, 60) capable of being moved in a joining direction (2) toward each other, and comprising at least two mold elements (30, 40), of which a first mold element (30) is attached to the first supporting unit (10, 20) and a second mold element (40) is secured to the second supporting unit (50, 60), which mold elements (30, 40) each have a mold recess (33, 43), which mold recesses (33, 43) in the mold elements (30, 40) together define the shape of at least one casting core to be produced (90) when the first and second mold elements (30, 40) bear against each other.

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: The invention relates to a method and tools for producing a braking band (2) of a disk-brake disk (1) by casting, in which the disk comprises at least two plates (3, 3?) connected to one another by connecting elements (4) forming an internal air-duct (7) for the cooling of the braking band (2). With the method and the tools, a disk is produced in which at least one of the plates (3, 3?) has, in its surface (8, 8?) defining the air-ducts (7), at least one groove (10, 10?) having a cross-section which becomes wider towards the air-duct.

Abstract: A method for producing sand cores for foundry, comprising the operations of: defining a molding cavity; blowing in a mixture of sand and hydrated binder into said molding cavity so as to produce a mass of sand, which reproduces in a complementary way the shape of said molding cavity; and producing the passage, through said mass of sand, of a flow of aeriform along at least one principal direction. The method comprises the operation of generating through said mass of sand a flow of aeriform, directed at least in part in a radial direction with respect to said principal direction.

Abstract: A method for producing sand cores for foundry, comprising the operations of: defining a moulding cavity; blowing in a mixture of sand and hydrated binder into said moulding cavity so as to produce a mass of sand, which reproduces in a complementary way the shape of said moulding cavity; and producing the passage, through said mass of sand, of a flow of aeriform along at least one principal direction. The method comprises the operation of generating through said mass of sand a flow of aeriform, directed at least in part in a radial direction with respect to said principal direction.

Abstract: A machine for production of cores for use in castings includes a platform for supporting two core boxes and a split filler head having dual discharge channels for simultaneously injecting core sand into two core boxes and for simultaneously applying curing gas to core sand injected the two into core boxes.

Abstract: The present invention relates to a method and apparatus for making a sand core (112) utilizing purge air through a core box (100 and 100′) to harden the binder in the sand core (112) proximate the ejection pins (106 and 106′). The sand core (112) may be removed from the core box (100 and 100′) prior to drying the binder completely thereby resulting in an improved production rate of the sand core (112).

Abstract: The present invention relates to a method and apparatus for making a sand mold (112) utilizing reverse purge air through a core box (100 and 100′) to harden the binder in the sand mold (112) proximate the ejection pins (106 and 106′). The sand mold (112) may be removed from the core box (100 and 100′) prior to drying the binder completely.

Abstract: A method of making a ceramic core is provided wherein the ceramic core is grit blasted using abrasive grit media particulates directed at the core through a preformed apertured mask or pattern to impart a controlled pattern of surface concavities to the core surface by impingement of the abrasive grit media thereon. Another method of making a ceramic casting core is provided wherein the ceramic core is formed in a molding die having a fugitive textured mask or a permanent textured insert positioned on the die surface to impart a controlled surface texture or roughness to the core surfaces.

Abstract: An apparatus for curing foundry cores 100 is provided, including a first curing agent supply 110 passing through foundry core 145 primarily through first directional plane 130 and a secondary curing agent supply 160 passing through the foundry core 145 primarily through a secondary directional plane 170.

Abstract: Method and apparatus for making a ceramic core or fugitive pattern for use in investment casting wherein a fluid ceramic core or pattern material is introduced into a molding cavity defined by cooperating dies, and at least a region of one or both of the dies is heated during filling of the molding cavity with the material and then cooled to a lower ejection temperature before removal of a ceramic core or pattern from the molding cavity.

Abstract: The invention relates to a device for casting a workpiece, especially a turbine blade with inner cooling, comprising a casting cavity (1) in which casting cores (2) which produce channels (3) that pass through the workpiece are provided. The aim of the invention is to improve a device of this type in such a way that there are no poorly cooled areas present in the workpiece. To this end, the casting cores (2) are placed in the casting cavity (1) in such a way that they rest against each other loosely.

Abstract: An engine block mold package includes a barrel crankcase core having a plurality of barrels on an integral crankcase region and one or more locator surfaces on the crankcase region. The barrels are formed by a barrel-forming tool element of a core box. The barrel-forming tool element is configured to also form the locator surface(s) on the crankcase region such that the locator surface(s) is/are accurately positioned relative to the barrels and thus the cylinders formed in the engine block cast in the mold package. The locator surface(s) can be used to locate the engine block casting in subsequent aligning and machining operations without the need to reference a curved surface of a cylinder bore liner.

Abstract: An apparatus for curing foundry cores 100 is provided, including a first curing agent supply 110 passing through foundry core 145 primarily through first directional plane 130 and a secondary curing agent supply 160 passing through the foundry core 145 primarily through a secondary directional plane 170.

Abstract: A method for the production of a cast article having a small hole comprises the steps of setting a linear core member in a cavity of a metal mold, injecting a molten metal into the cavity, and drawing out the core member from the resultant cast product to form a small hole. A linear core member having a surface film formed by surface coating or by subjecting to a surface treatment is used so that the surface film is partly or as a whole peeled off the linear core member upon drawing it from the cast product, thereby enabling the core member to be drawn from the inside of the cast product. Alternatively, the linear core member is so constructed as to elastically deform in the drawing direction upon drawing it from the cast product to have a diameter smaller than the original diameter.

Abstract: The invention relates to a method for the production of core preforms for foundry in which a) a mixture of inorganic, refractory foundry sand and a water glass-based inorganic binder is produced, b) the mixture is poured into a heated core box c) the water contained in the mixture is withdrawn by a physical method and d) the core preform is taken out of the core box. The process is characterized by the fact that e) the heated core box is subjected to a depression during filling f) the temperature/dwell time is adjusted after the closing of the core box so that a dimensionally stable and good bearing shell is formed on the edge of the preform g) the preform is immediately removed after opening of the core box and, under the effect of microwaves, is subjected to a complete drying.

Abstract: A process for the manufacture of a thin ceramic core involves casting a band of uniform thickness on a support from a solution of a ceramic material based on silica and zircon in a binder, drying the band, shaping the band in a mold and carrying out preheating and pressing of the band in the mold, baking the component thus obtained in a ceramic preform, and then carrying out an impregnation. The thin core obtained can be assembled together with another thin core and/or on a conventional thick central core, and can be used in precision casting such as in the production of turbine blades.

Abstract: A process for inserting cores into a casting mold includes inserting a plurality of individual cores into a template; forming a core group by joining together the plurality of individual cores within the template using a bracing and securing device which is detachable; dipping the core group into a founder's black bath to provide a coated core group; drying the coated core group; inserting the core group after drying into the casting mold; and removing the bracing and securing device. The process advantageously additionally includes providing a plurality of core groups that form a core assembly for a casting mold; forming a core set by joining together the plurality of core groups using a bracing and securing device; dipping the core set into a founder's black bath to provide a coated core set; drying the coated core set; inserting the core set after drying into the casting mold; and removing the bracing and securing device.

Abstract: A cope for a core box has a passage for passing sand into a core box cavity and a bore for passing catalyst into the core box cavity to harden a sand core formed therein. The bore may extend from an exterior surface of the cope to the cope passage. The cope may have structure for forming a seal with a sand injection tube following sand injection, such as a blow-up seal or an O-ring. A method of producing cores in a core box includes the step of providing a cope, a drag, and a cavity formed therebetween, the cope having a passage for receiving an injection tube and a bore for passing catalyst. Further steps include using the injection tube to inject sand through the cope passage into the cavity and passing catalyst through the bore in the cope into the cavity. A seal may be formed between the cope and the injection tube after sand injection.

Abstract: A core box assembly for molding cores includes a first core box and a second core box disposed above the first core box. Each of the core boxes has a cavity. A passage for delivering core material to the cavities in the core boxes extends through the second core box and into the first core box. The second core box is placed above the first core box and core material is injected into the core boxes.

Abstract: The core box includes a cavity therein, a vent in fluid communication with the cavity, ejector members, and apparatus coupled to the ejector members for passing a fluid through the vent into the cavity.

Abstract: A process of core molding is disclosed, which permits increasing the positioning accuracy of a base core and a bonded core relative to each other and also avoids handling the first molded base core outside the die to preclude such trouble as breakage of the common die. By the process, a complete core is obtained, which comprises a base core and a bonded core positioned in and bonded to the base core. The base core is molded in a molding space which is defined by engaging a die element and a common die with each other. After removing the die element from the common die while leaving the molded base core in the common die, a different die element is engaged with the common die to define a different molding space for molding a bonded core. The bonded core is bonded to the base core as it is molded.

Abstract: A method and apparatus for fabricating a core within a core box 10 having passages and screens 12 through which an air-sand mixture may flow to occupy cavities within the core box 10 by which the core is shaped. The method comprises providing a plurality of pressure switch sensors 14 disposed upon a core replica 16, each sensor being located in communication with a screen 12 within the core box 10; positioning the replica 16 within the core box 10; monitoring a condition at one or more screens 12 to determine a state of accretion thereat and generating a signal indicative of the condition; sending the signal to a processor which is in operative communication with a means for cleaning; and activating the means for cleaning within the core box 10 in response to the signal so that flow impediments are cleared from the screens 12 and so that constrictions in fluid flow within the core box 10 are detected in their early stages of development and acceptable production rates may be maintained.

Abstract: A core box has a thick walled cope and a thin walled metal drag mating in essentially a horizontal parting plane. The cope and drag each have ports therethrough screened to prevent passage of sand, the ports communicating with the interior of the core box. Resilient seals seal and reseal the cope and drag at the parting plane. A convection heater delivers a heated gas, to drag ports and thence out through the ports of the cope, the convection heater having a heat conductive manifold attached to and along the drag for augmenting the heat of the gas as it passes to the ports of the drag. Conduction heater (burner units) directly heats both the cope and manifold and thereby the interior of the core box by conduction. The convection heater heats the gas in two stages, first to a temperature level outside the core box and manifold and thence to a second temperature level elevated by exposure to the manifold. The temperature levels are respectively about 175.degree.-225.degree. F. and 250.degree.-290.degree. F.

Abstract: A method and apparatus for the manufacturing in one operation of a complex core, such as a core for manufacturing a double-volute turbo-charger housing. The apparatus includes two separable core box halves and a segmented mandrel removably disposed between the two separable core box halves. The mandrel has two removable segments which allow for the removal of a completed core.

Abstract: A gas-permeable form tool for manufacturing casting and core moulds from hardenable moulding sand includes a heteroporous, open-pore material. The wall of the tool contains a first fine-pore layer region adjacent to the moulding sand with a thickness of about 0.2-2 mm and a material density of about 75% to 95% of theoretical specific density and a pore diameter of about 50 .mu.m. The first fine-pore layer comes in contact with a second, large-pore supporting skeleton having a theoretical material density of less than 80% of theoretical specific density and a median pore diameter of more than 100 .mu.m.

Abstract: An improved core making machine having a frame and capable of producing cores at a molding position within the frame is easily configured to include one or more horizontal core box handling components and/or one or more vertical core box handling components. The machine is readily adaptable to many different foundry needs.

Abstract: A foundry core blowing machine includes an upright frame with a blow head for a sand-resin mix fixed at the top. Sectionalized vertically movable rods extend through bushings at the top and bottom of the frame. Fixed to the rods are a cope support and a secondary table. The secondary table supports the cylinder of a cope-drag clamp piston-cylinder assembly with the rod of such assembly being connected to a primary table thereabove which slidably moves on the rods. The secondary table and the rods secured thereto are elevated independently of the cope-drag clamp so that the clamped cope and drag may be elevated to be clamped against the blow head, lowered for interposition of a gassing head, and reclamped for cure, all while the cope and drag remain firmly clamped together. Only after curing are the cope and drag unclamped for lowering, stripping and removal of the core from the machine.

Abstract: A core box shuttle system includes a shuttle car movable along a path, a movable shaft, a guiding surface carried by the shuttle car having a longitudinal extent transverse to the path and a slip-type connection between the movable shaft and the guiding surface whereby movement of the movable shaft is converted by the slip-type connection into movement of the shuttle car along the path.

Abstract: In a core blowing machine, a core collecting device including a plurality of core collecting trays is provided, which is positioned at a core removal area of the machine and comprises a support bed on which a first set of guides is provided for guiding a carriage in a longitudinal direction thereof. A frame common for all core collecting trays is integrally connected to the carriage. The frame has a second set of guides which are transversal to the first set. A slide block is positioned on each pair of transversal guides and a tilting support holding the corresponding tray is fitted on each slide block. A tilting cylinder is provided for each tray, which is connected between the slide block and the support.

Abstract: A foundry core blowing machine includes an upright frame with a blow head for a sand-resin mix fixed at the top. Sectionalized vertically movable rods extend through bushings at the top and bottom of the frame. Fixed to the rods are a cope support and a secondary table. The secondary table supports the cylinder of a cope-drag clamp piston-cylinder assembly with the rod of such assembly being connected to a primary table thereabove which slidably moves on the rods. The secondary table and the rods secured thereto are elevated independently of the cope-drag clamp so that the clamped cope and drag may be elevated to be clamped against the blow head, lowered for interposition of a cure head, and reclamped for cure, all while the cope and drag remain firmly clamped together. Only after curing are the cope and drag unclamped for lowering, stripping and removal of the core from the machine.

Abstract: The system includes two platforms vertically movable along guides provided on a fixed support. A top platform is swingable between a horizontal position in which it superposes a lower platform, and a vertical position. A blowing plate is positioned on the top platform. The system is provided with a double catch which is selectively engageable with the bottom wall of the top platform when the latter is in the horizontal position, and with the fixed support when the top platform is in the pivoted-away position.

Abstract: A core machine is arranged to automatically refine the shape of a sand core upon removal of the core from the machine. The core machine uses a core box to form a core. After formation of the core and separation of the core box halves a shaping member is moved into a space between the core box halves. As the core is ejected from the core box and removed from the machine it passes through the shaping member which refines the shape of the core. The machine may also be used for dimensional tolerancing about the parting line of the core box.

Abstract: A machine and method for making molds and mold cores (126) includes a pair of mold boxes (42a, 42b) removably mounted on a frame (60) for rotation between an upright, molding position in which molding material is introduced into the mold cavity of the mold boxes (42a, 42b) by a carrier (26) and an inverted discharge position in which the mold (126) is removed from the boxes by a mold receiving assembly (76). A pressure head assembly (46) both compresses molding material within the mold cavity and introduces a catalyst gas into the cavity for curing the molding material. A system for removing the spent gas from the mold cavity includes a pair of gas receiving chambers (122a, 122b) integral with the frame (60) which receives gas through the bottom of the mold boxes (42a, 42b) and an exhaust assembly (68, 70) which is selectively coupled with exhaust ports (124a, 124b) in the chambers (122a, 122b).