Abstract: A method for creating undercut features in a wax pattern in an investment casting process is disclosed. The method comprises designing a tooling that includes a mold for an object with an aperture and a core corresponding in size and shape of the aperture. Then, the mold is used to injection mold a pattern for the object, wherein the pattern includes an opening corresponding to the aperture. Next, a plug from the core of the tooling is injection molded using the mold. The plug is press-fitted into the opening of the pattern and the opening of the pattern is sealed with the plug.

Abstract: A mold for manufacturing a composite drive shaft, most of which, except for opposite ends functioning as power transmission parts, has a tubular shape with a circular cross-section similar to that of a general shaft, and the shape of each end of which is changed so as to realize easy removal of the drive shaft from the mold after molding. Further, the present invention provides a composite drive shaft, which is manufactured using the mold and is configured such that, when a connection joint (metal yoke) is assembled with each end of the drive shaft, the drive shaft can be rotated in an integrated state realized by the connection joints. Thus, the composite drive shaft of the present invention can directly transmit power, instead of a mechanical fastening jointing technique or an adhesive bonding jointing technique, thus efficiently transmitting high torque.

Abstract: A method for producing a cast body having a thin portion is provided, including subjecting a thin member of iron, copper, or nickel alloy to metal-ceramic insertion in a matrix of iron or copper. In the method, the thin member including a ceramic layer on the surface thereof to prevent the thin member from melting upon metal-ceramic insertion. Alternatively, a ceramic layer is formed by using a thin member containing 0.5 wt % or more in total of at least one element selected from the group consisting of Al, Ti, Be and Mg, at least on or near a surface of the thin member, either at the time metal-ceramic insertion or at the time of heating prior to metal-ceramic insertion to prevent the thin portion from melting upon metal-ceramic insertion.

Abstract: A method of manufacturing a brake pad comprising casting a back plate in a mould. The plate is formed with at least one integral projection which overhangs an adjacent surface of the plate. The mould is formed from frangible material and has a recess in the shape of the projection. The mould is formed from particulate material compressed around a projection made of resilient material which deforms to the shape of the projection. The resilient material is withdrawn to form the recess. Metal is cast in the mould including the recess. After solidification of the metal, the mould is broken away from the projection. The method also comprises pressing a mixture containing friction material and curable material against the plate including pressing the mixture around the projection so that it extends beneath the overhang and curing the curable material to form a block of friction material adhered to the plate.

Abstract: An evaporable foam pattern for casting a metal water-cooled exhaust manifold for an internal combustion engine. The assembled pattern is formed of an evaporable foam polymeric material, such as polystyrene, and includes an inner exhaust conduit composed of a generally upright body portion and a generally curved elbow portion. The body portion is provided with a plurality of inlet ports connected to the exhaust passages of a bank of cylinders, while the elbow portion defines a downwardly facing outlet. The pattern also includes an outer water jacket which is spaced from the exhaust conduit to provide a water passage therebetween. Both the exhaust conduit and the outer jacket are composed of two longitudinally split halves or sections having abutting edges, and the abutting edges are joined together by an adhesive. Spacing ribs interconnect the inner surface of the jacket and the outer surface of the exhaust conduit to space the sections apart.

Abstract: A pattern plate for making moulds intended for use in the production by sand casting of window seals or similar articles having an undercut bead, includes a plate, a fixed exterior part, an axially movable interior part and a elastomeric ring connecting the interior and exterior part. The interior part moves axially over a short path defined within the exterior part by mechanical stops between an extended position, to which it is pushed back by springs, and a retracted position which it assumes through the action of the compaction pressure. During compaction, an annular elastomer ring located between the interior and exterior parts compresses to compact the mold material in a lateral direction. Upon release, the elastomeric ring returns to its original position facilitating the removal of the mould.

Abstract: A mold forming tool for use in the manufacture of casting molds by compression of loose mold forming material by a process in which the final compacting is achieved by pressing, for the casting of cast pieces having undercuts, the tool having an elastically deformable portion in the region of the undercuts, and the elastically deformable portion being made of a material which is deformable, thus creating the undercut pattern, solely under the influence of the pressure exerted on the mold forming material during the final compacting.

Abstract: A method of preparing an assembly and an assembly useful in making a mold for casting one-piece impellers in which a master model of one of the vanes of the impeller is made in a polished metal having, on its inner end a shoulder with a height and depth approximately equal twice the width of the vane at its inside edge, the vane being tapered from inside to outside; from the master model a plurality of identical, flexible vanes are prepared from a material selected from the group consisting of flexible rubber and flexible plastic; a member having a truncated conical part containing therein a plurality of slots sized to match the inner edge of the vanes and a base plate having a plurality of slots therein equal in number to the slots in the truncated conical part with the slots in the truncated conical part and the base plate in alignment is formed; the flexible vanes are inserted from inside the truncated conical part through the slots therein with the bottom portion of the vanes in the slots in the base plat

Abstract: An annular member is integrally positioned within a core portion so that a side surface of the annular portion coacts with the outer surface of the core portion to form a substantially smooth and continuous outer surface of a core. A substantially inextensible portion of the annular member is joined in end-to-end relation to an elastomer portion of the annular member. An axial end portion of the elastomer portion is mechanically locked to the core portion.

Abstract: Apparatus for molding, for example, a seamless brake drum female mold having a plurality of radially inwardly extending grooves and ridges. The apparatus includes a generally hollow one-piece distensible and flexible hollow male mold having an annular side wall having a plurality of radially extending projections and undercuts and includes an outer core box positioned around the flexible mold and defining an annular cavity with it. The apparatus further comprises a packing mandrel for supporting the hollow flexible mold while mold material is packed around it and a vacuum mandrel to be inserted within the flexible mold to cause the collapse of the flexible mold so that the molded article can be lifted off the flexible mold despite the radially extending projections.