Abstract: A vacuum smelting device with mold-temperature control design includes: a chamber body and a cabin door, wherein the chamber body and the cabin door form a vacuum closed space; a smelting crucible disposed in the vacuum closed space for smelting raw materials to a molten metal; a casting mold also disposed in the vacuum closed space for accommodating the molten metal poured from the smelting crucible, and solidifying the molten metal to an as-cast alloy; and a mold-temperature control module surrounding the casting mold for controlling the temperature of the casting mold.

Abstract: A jewelry item includes a ring-shaped base, a single center setting and a plurality of side settings. The ring-shaped base has a central opening and a central axis. The single center setting has a plurality of primary prongs for securing a center stone. The plurality of side settings is configured for securing an equal plurality of side stones around a perimeter of the center setting, wherein each side setting includes first and second adjacent inner secondary prongs and first and second adjacent outer secondary prongs. The jewelry item may be a ring having a band to be worn about a finger of a person. Shoulders and struts may secure the ring-shaped base above the band.

Abstract: A method of forming a component having an internal passage defined therein includes positioning a jacketed core with respect to a mold. The jacketed core includes a hollow structure that includes an interior portion shaped to define at least one interior passage feature of the internal passage. The jacketed core also includes an inner core disposed within the hollow structure and complementarily shaped by the interior portion of the hollow structure. The method also includes introducing a component material in a molten state into a cavity of the mold to form the component, such that the inner core defines the internal passage including the at least one interior passage feature defined therein.

Abstract: A method of forming a component having an internal passage defined therein includes positioning a jacketed core with respect to a mold. The jacketed core includes a hollow structure formed from at least a first material and a first catalyst, and an inner core disposed within the hollow structure. The method also includes introducing a component material in a molten state into a cavity of the mold, and cooling the component material in the cavity to form the component. The inner core defines the internal passage within the component.

Abstract: A method of forming a component having an internal passage defined therein includes positioning a jacketed core with respect to a mold. The jacketed core includes a hollow structure formed from at least a first material and a second material, and an inner core disposed within the hollow structure. The method also includes introducing a component material in a molten state into a cavity of the mold, and cooling the component material in the cavity to form the component. The inner core defines the internal passage within the component.

Abstract: A method of forming a component having an internal passage defined therein includes positioning a jacketed core with respect to a mold. The jacketed core includes a hollow structure formed from a first material, an inner core disposed within the hollow structure, and a core channel that extends from at least a first end of the inner core through at least a portion of inner core. The method also includes introducing a component material in a molten state into a cavity of the mold, such that the component material in the molten state at least partially absorbs the first material from the jacketed core within the cavity. The method further includes cooling the component material in the cavity to form the component. The inner core defines the internal passage within the component.

Abstract: The present invention provides a method for producing Cu67 radioisotope suitable for use in medical applications. The method comprises irradiating a metallic zinc-68 (Zn68) target within a sealed ceramic capsule with a high energy gamma ray beam. After irradiation, the Cu67 is isolated from the Zn68 by any suitable method (e.g. chemical and or physical separation). In a preferred embodiment, the Cu67 is isolated by sublimation of the zinc in a ceramic sublimation tube to afford a copper residue containing Cu67. The Cu67 can be further purified by chemical means.

Abstract: An investment casting method for a cast ceramic core (110), including an airfoil portion (116) shaped to define an inner surface (56) of an airfoil (52) of a vane segment (50) and an integral shell portion (122) having a backside-shaping surface (120) shaped to define a backside surface (68) of a shroud (62) of the vane segment. The backside-shaping surface has a higher elevation (132) and a lower elevation (134). The higher elevation is set apart from a nearest point (138) on the airfoil portion by the lower elevation. The airfoil portion and the shell portion are cast as a monolithic body during a single casting pour.

Abstract: A ceramic core includes sintered ceramic powder and a hole opening on a surface of the ceramic core and having an opening portion with a maximum size of 100 ?m or less. A manufacturing method for a ceramic core includes: preparing an injection molding composition by mixing ceramic powder and a binder; manufacturing a ceramic compact by performing the injection molding of the injection molding composition; and manufacturing a ceramic core by sintering the ceramic compact, wherein cumulative percentage of coarse powder with a particle diameter of more than 50 ?m included in the ceramic powder is 30% or less on an integrated volume particle size distribution curve of the ceramic powder.

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 method of using a bonded refractory mold is disclosed. The method includes forming a refractory mold including a mold wall on a fugitive pattern including a thermally removable material. The mold wall including a refractory material and defining a sprue, a gate and a mold cavity, the gate having a gate inlet opening into the sprue and a gate outlet opening into the mold cavity; a gas vent extending through the mold wall; and a gas permeable refractory material covering the gas vent, the fugitive pattern having a sprue portion, the sprue portion having a sprue channel that is in fluid communication with a sprue inlet and that extends toward a sprue outlet. The method also includes heating the refractory mold with a hot gas to remove the thermally removable material, wherein a portion of the hot gas is exhausted from the refractory mold through the gas vent.

Abstract: A method of making a bonded refractory mold is disclosed. The method includes forming a fugitive pattern including a thermally removable material. The method also includes forming a refractory mold including a mold wall, the mold wall including a refractory material and defining a sprue, a gate and a mold cavity, the gate having a gate inlet opening into the sprue and a gate outlet opening into the mold cavity, the mold defined by the fugitive pattern. The method further includes forming a gas vent that extends through the mold wall. The method also includes covering the gas vent with a gas permeable cover.

Abstract: A mold in which a fine uneven structure is formed on the surface by anodizing a surface of an aluminum base material having a purity of equal to or more than 99.5% by mass, wherein a 60-degree gloss of the surface on the side where a fine uneven structure is formed is equal to or more than 750%.

Abstract: A method of using a bonded refractory mold is disclosed. The method includes forming a refractory mold comprising a mold wall on a fugitive pattern comprising a thermally removable material, the mold wall comprising a refractory material and defining a sprue, a gate and a mold cavity, the gate having a gate inlet opening into the sprue and a gate outlet opening into the mold cavity; a gas vent extending through the mold wall; and a gas permeable refractory material covering the gas vent, the fugitive pattern having a sprue portion, the sprue portion having a sprue channel that is in fluid communication with a sprue inlet and that extends toward a sprue outlet. The method also includes heating the refractory mold with a hot gas to remove the thermally removable material, wherein a portion of the hot gas is exhausted from the refractory mold through the gas vent.

Abstract: A method of making a bonded refractory mold is disclosed. The method includes forming a fugitive pattern comprising a thermally removable material. The method also includes forming a refractory mold comprising a mold wall, the mold wall comprising a refractory material and defining a sprue, a gate and a mold cavity, the gate having a gate inlet opening into the sprue and a gate outlet opening into the mold cavity, the mold defined by the fugitive pattern. The method further includes forming a gas vent that extends through the mold wall. The method also includes covering the gas vent with a gas permeable cover.

Abstract: Disclosed is a method of manufacturing an impeller or a turbine wheel having a disk hub and an air foil. The method includes forming a mold for casting including a cavity of a shape corresponding to the rotor, arranging a core at a location corresponding to an inside of the rotor in the cavity of the mold for casting, injecting molten metal into the mold for casting where the core has been arranged, and removing the core from a casting which has been cast in the mold for casting.

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: Shell molds and processes for making the shell molds that exhibit high emissivity in the red and infrared regions. In this manner, thermal resistance within a gap formed between solidifying cast metal and the interior mold surface is decreased. In one embodiment, the facecoat region is formed from a slurry composition comprising an aluminum oxide, a green chromium oxide and a silicon dioxide. In another embodiment, the facecoat region is formed from a slurry composition including zirconium silicate and silica with stucco layer of alumina is included.

Abstract: An insulated investment casting shell mold is made by first mixing at least one refractory material with a slurry vehicle forming a prime coat slurry, and optionally mixing at least one refractory material with a slurry vehicle forming a backup slurry. The prime slurry is coated onto a fugitive pattern and optionally dried and/or stuccoed wherein the stucco has at least one refractory material. Optionally, at least one coat of the backup slurry is applied to the prime coated fugitive pattern and optionally dried and/or stuccoed after each coat of the backup slurry. The backup and stucco may be applied a plurality of times to obtain a desired shell wall thickness. An insulating slurry is formed by introducing gas into a slurry vehicle having at least one refractory material and containing a stabilizer and a foaming agent wherein gaseous bubbles become entrained therein forming an insulating slurry having closed porosity therein.

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: 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: Methods of forming modulated capacity scroll compressors are provided, where at least two distinct mold shapes are formed of foam material and then joined together to form a mold assembly. The mold assembly defines one or more substantially horizontal features, such as a horizontally oriented fluid passage or a weight-reduction recess in a solid wall. In certain aspects, the mold assembly defines a junction between a portion of a horizontal fluid passage and a portion of a vertical fluid passage. A molten metal displaces the foam material of the mold assembly to solidify and form the scroll component.

Abstract: A cast metal article, such as a turbine engine component, is made by shaping a body of refractory metal particles to form a molded refractory metal article. The molded refractory metal article is sintered to form a refractory metal core. Both the refractory metal article and a setter block may be sintered at the same time. At least a portion of the refractory metal core is enclosed with wax. The wax is at least partially enclosed with a covering of mold material. The wax is removed from the mold material to form an article mold cavity. The article mold cavity is filled with molten metal which solidifies to form a cast metal article. The refractory metal core is removed from the cast metal article.

Abstract: The object of the present invention is to provide a mold which has low reactivity with molten alloys and which is inexpensive, a method for manufacturing the same and a molded article using the mold. A mold 40 in accordance with the present invention serves for manufacturing a molded article 60 of a titanium-aluminum alloy or a titanium alloy. At least an initial layer 44a of a cavity surface 43 of a mold body 41 constituting the mold 40 is formed of a calcined product of a slurry comprising a filler having cerium oxide as a main component and a binder having silica sol as a main component.

Abstract: In-Place Cope Molding or “IPCM,” is designed to reduce or eliminate certain inefficiencies present in traditional molding techniques during production of the cope half of a sand mold. IPCM allows the cope half of the mold to be produced on top of the drag half of the mold by use of a separation barrier which supports the sand above the mold cavity in the drag. This method reduces or eliminates parting line flash, and also avoids the need to turn over or otherwise handle the cope, allowing the cope to be made thinner than a traditional cope and allowing for lower material costs.

Abstract: A substrate is coated by applying an essentially pure aluminum first layer to a surface of the substrate. At least a first portion of the first layer is oxidized so as to provide a protective coating of desired properties. The substrate may be a refractory metal-based investment casting core.

Abstract: A method to recover wax from wax patterns used in investment casting using a lost wax technique without damaging incorporated ceramic cores is disclosed that includes subjecting the wax pattern to specific conditions. These conditions include chilling a casting tool including the wax pattern and ceramic cores such that a brittle transition temperature for the wax material is approached. Once chilled the wax pattern is subjected to brittle fracture release of the wax from the underlying ceramic cores without damage to those cores.

Abstract: A substrate is coated by applying an essentially pure aluminum first layer to a surface of the substrate. At least a first portion of the first layer is oxidized so as to provide a protective coating of desired properties. The substrate may be a refractory metal-based investment casting core.

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 molding and transporting apparatus comprises a molding section for vertically blowing sand from above between a front die and a rear die that have vertically formed pattern faces, and thereafter, driving the front and rear dies and compacting the sand to produce a mold M, and for extruding the mold horizontally, a dividing mechanism for, before the sand is blown, vertically dividing the mold into front and rear portions, as needed, at the center of a molding space, a pouring port formation mechanism for forming a pouring port in the mold; and a form converter for selectively rendering an active operation for changing the form of the mold that is extruded from the molding section from the vertically split form to the horizontally split form, and a non-active operation for transporting the extruded mold to a pouring line, without changing the form of the mold.

Abstract: A method for molding gemstone settings using metal molds is provided. The gemstone settings have unitary seats on the prongs of the settings. The method involves using a core pin mold to form a core pin which is interengageable with a metal production mold for the setting. A gemstone setting is also provided, with a substantially smooth inner prong surface. The gemstone setting provides substantially stronger set gems and reduces the incidences of shattering gems during the setting process.

Abstract: A metallic mold for tire curing is disclosed, which comprises a plurality of pieces for forming a tread pattern of a tire by sections, the pieces being fixed to a back block and arranged in an annular form. In this case, each piece is composed of a plurality of piece block layers laminated by performing a plurality of shots of die casting for metallic materials, and a very small gap is formed in a joined portion between the piece blocks by means of coagulation and contraction of the metallic materials. Because of this constitution, formation of a gap having necessary exhaust performance in an optional position of a molding surface can be facilitated. Accordingly, an appearance of a produced tire can be improved without preventing spew formation, and the production of defectives can be reduced during curing and molding.

Abstract: A method of fastening core elements together without the use of foreign agencies, such as adhesives, screws or other such fasteners, uses the same core sand and resin that form the core elements themselves. Core sand elements are retained in an assembly by bodies of cured core sand and resin in holes or cavities that span the interface between the core elements and fasten the core sand elements together. Core sand elements are provided with alignable holes, or cavities, into which a mixture of core sand and a curable resin, preferably the same resin used in forming the core sand elements, is added and the curable resin is cured to provide a body of cured core sand and resin, preferably adhering to the core sand elements, fastening the core sand elements together.

Abstract: A pouring method and a pouring plant are described. Mould sections (15) are produced piecewise with cavities at two opposite ends thereof. The mold sections are combined in a line (15A-15D), wherein the cavities define a mold cavity (15a) having an exposed pour cup (30). The line of mold sections is advanced incrementally by drive means (16, 162) through an increment length that corresponds to the length of the mold sections (15), to and through a molding station (50). The true lengths of the produced sections (15) are measured and registered. The difference in length between the first mold section (15D) in the line (15A-15D) that lies immediately upstream of a pour cup (30), where a pouring operation was last carried out, and the last mold section (15A) in the line is calculated.

Abstract: A process for making a casting mold or core utilizes a refractory composition including a slurry of yttria, an acid and an organic solvent. The composition is applied to a mold or pattern, dried, and fired to produce a mold or a layer of a mold or core. The articles produced are relatively unreactive with titanium and titanium alloys during casting.

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: When compacting mold sand in a mold chamber (not shown) to form a mold or mold part (not shown) by using two co-operating squeeze plates with associated patterns (not shown), in which one squeeze plate is actuated before the other one, the second squeeze plate is not acuated until the pressure in the mold chamber (or a parameter depending on or derived from this pressure) has reached a predetermined value. By proceeding in this manner it is possible to manufacture molds or mold parts in series with practically the same hardness or solidity.

Abstract: An improved method for producing one-piece cutter body members for comminuting apparatus for shredding, crushing and grinding bulk solid waste materials is provided. The process creates one-piece cutter body members having cutter teeth distributed along the length of the body members for rotation when in fixed engagement with twin or multiple parallel shafts of the bulk solid waste material comminuting apparatus. The resulting one-piece cutter body members are adaptable to intermeshing comminuting action each having cutting teeth which may be shaped for cutting in both of two opposite directions of rotation.

Abstract: Emissive compositions are described that can be applied as a coating to the surface of an investment casting mold to increase or decrease the rate of cooling of a casting within the mold. A coating that decreases the rate of cooling of an investment casting within an investment casting mold may comprise a compound having an emissivity less than the emissivity of the mold; a high temperature glass-forming material and a solvent to make a slurry. Similarly, a coating that increases the rate of cooling may comprise a compound having an emissivity greater than the emissivity of the mold; a low temperature glass-forming material and a solvent to make a slurry. Also disclosed in a method of investment casting wherein an emissive composition is applied to the investment casting mold.

Abstract: An assembly for making a wax pattern of a hollow component includes a pattern die and a noncircular core which is located within the pattern die. The pattern die is a split die and includes two halves which have shaped internal surfaces to define the external shape of the wax pattern of the hollow component. The core has shaped external surfaces which define the internal shape of the wax pattern of the hollow component. The core has coaxial circular cross-section projections which locate within correspondingly shaped and dimensioned apertures in the pattern die. One of the apertures in the pattern die has a radially extending pin which is arranged to mate in a groove on the projection to locate the core longitudinally. The core is allowed to rotate within the die so that chaplets on the core position the core accurately without imposing strains on the core.

Abstract: A method of making a complex ceramic core for use in a metal casting process of the lost wax type, the core having at least one recess which extends into the interior of the core and being intended for use in the manufacture of a hollow component having internal cavities and partitions, including successive and superimposed injections of at least two compounds, one of which is degradable without harming the other(s), in at least one mold to produce a solid body wherein the other(s) of the compounds forms said core and the degradable compound fills the recesses of the core. The first injection creates a blank from one or other of the compounds, and each successive injection forms a layer which covers, at least partly, the outer surface of the blank obtained after the preceding injection until the solid body is completed. The body is then treated to remove the degradable compound and thereby leave the desired complex core.

Abstract: Though holes are provided in a suitable area of the cores during the formation thereof in a first blowing machine, such that, on adjoining the cores, to form the block, and in the absence of additives between the contacting surfaces thereof, the through holes are placed one adjacent another. Then a housing is defined, which affects the entire block in a longitudinal direction, and which subsequently molds a mixture of sand and a binder material, similar to a core in a second blowing machine. The material after hardening, acts as a coupling and stiffening arrangement between the cores forming the block.

Abstract: Channels or apertures are provided in a suitable area of the cores during the formation thereof in a first blowing machine, such that, on piling of the cores to form the block, and in the absence of additives between the contacting surfaces thereof, the apertures or channels are placed one adjacent another. Then a housing is defined, which affects the entire block in a longitudinal direction, and which subsequently molds a mixture of sand and a binder material, similar to a core in a second blowing machine. The material after hardening, acts as a coupling and stiffening arrangement between the cores forming the block.

Abstract: An expendable substrate which in use contacts molten metal, for example a foundry mould or core or ladle lining, is coated with a coherent layer of refractory particles by tribo-electrically charging refractory particles coated with an organic binder, the coated particles having an electrical resistivity of at least 10.sup.10 ohm. cm. at 10kv, earthing the substate and bringing the charged particles into contact with the earthed substrate. Suitable binders are thermoplastic resins, thermosetting resins and waxes and the quantity of binder in the binder coated particles is usually less than 10% by weight.

Abstract: A binder for manufacture of a precision casting mold comprising a transparent solution containing an alkyl orthosilicate or an alkyl polysilicate having a polymerization degree of 2 to 10, and an amino-alkoxide of a metal selected from a group consisting of titanium, zirconium, tin and aluminum or a mixture thereof in the mol ratio (Si/N) of 0.01 to 1.0 calculated in terms of the silicon atom contained in the silicate and the basic nitrogen atom contained in the amino-alkoxide. This binder is excellent in preservation stability and workability and does not dissolve the surface of a water-soluble pattern.

Abstract: A process for producing a casting mould with chemically bound moulding material using a pattern is intended to make it possible to forego the use of clay-bound sand, in particular for the mass production of cast members, and to provide a casting mould of adequate gas permeability, which is simple to produce, with a low level of consumption of moulding material, and inexpensive, and which also provides a high level of casting quality wth a low degree of environmental pollution. For that purpose, the moulding material which has become pourable or fluid due to the operation of casting a cast member is removed from a first casting mould comprising a single moulding material, whereas the remaining portion of the moulding material is left, and the hollow space formed when the pattern is re-fitted is filled with moulding material. In addition, the moulding material which has been reduced in strength may be also removed, being for example blown or brushed out.

Abstract: Binder, filler, and refractory compositions and methods of using and making these compositions are disclosed. The binder composition comprises colloidal silica, a liquid material containing Si--OH groups, a solvent which is capable of solubilizing the liquid material and the colloidal silica, and at least one aprotic, non-ionic, non-metallic, organic compound which contains at least one element selected from phosphorus, sulfur, boron and nitrogen and which stabilizes the binder composition against self-gelling. The liquid material and the colloidal silica are present in a ratio by weight of from about 10:1 to about 1:10 respectively. The liquid material has at least about 20% by weight SiO.sub.2. The colloidal silica contains at least about 15% by weight SiO.sub.2.

Abstract: A process for manufacturing shell molds for investment casting using an artificial stucco material is disclosed. The stucco particles comprise refractory powder held together by a binder which volatilizes or otherwise disintegrates at firing temperatures. Since the particles lose their structural integrity in the firing process, the shell mold may be more easily broken away from the finished casting.

Abstract: A refractory suspension comprising (parts by weight): coke, 10-60; powdered metallic titanium or/and zirconium, +0.3-5.0; resol resins, 5-50; a hardener, such as an inorganic acid, 2-30; an organic solvent, 20-60.The proposed suspension allows making foundry moulds exhibiting a higher strength. The castings produced in said foundry moulds are superior in accuracy by 2 classes, according to the USSR classification, to those obtained by the prior-art methods.

Abstract: A machine for forming foundry moulds includes a turret supporting spaced mould frames, each of the latter having a mould portion formed therein by rotation of the turret toward a sand filling and compacting station and away therefrom. The completed mould portion may be moved to a position where a core can be set thereon and then moved to a position where the mould portions are positioned one atop another to make a stack of finished and cored moulds. When the moulds are not cored, a pair of said filling and compacting stations are provided, the turret oscillating or rotating unidirectionally from a loading position to a delivery position. Where a pair of filling and compacting stations are provided for forming cope and drag mould portions, the turret oscillates to place the two mould portions in proper position to form a mould comprised of cope and drag portions.