Abstract: The subject matter of the invention are sizing compositions containing an aqueous carrier liquid, refractory base materials and CH-acidic compounds, as well as their use for casting molds, as well as casting molds coated with the sizing composition.

Abstract: A method and system for manufacturing a cast iron crankshaft for a vehicle are provided. The system comprises a molding unit arranged to form a negative sand cast mold of the cast iron crankshaft. The mold comprising at least one molded cavity having a pattern with dimensions of the cast iron crankshaft. The system further comprises a feeding mechanism comprising a riser having a connector through which molten metallic material flows to the cast mold. The feeding mechanism feeds the molten metallic material at a riser connection angle in the at least one mold cavity. The riser connection angle corresponds to a connector modulus. The connector modulus is 20% greater than a cast modulus. The riser geometry corresponds to a riser modulus. The riser modulus is 20% greater than the connector modulus. The system further comprises a furnace, a cooling area, a separation unit, a controller and a power source.

Abstract: An investment casting pattern including: a consumable body formed of: a first body portion; and a second body portion; and a fastener arranged to form an interface between the first body portion and the second body portion, and to locate the first body portion relative to the second body portion, wherein the fastener is formed of a different material than the first body portion and the second body portion.

Abstract: Refractory slurry for use in coating a foam cluster to provide a foam pattern for lost foam casting is provided. The slurry includes a catalyst capable of catalyzing reactions for vaporizing the foam cluster. A foam pattern with a refractory coating including the catalyst and processes for preparing the foam pattern and using the foam pattern are also provided.

Abstract: A method of manufacturing a golf club head can include: creating a mold of the golf club head; forming two or more portions of a model of the golf club head using the mold, each of the two or more portions of the model include a part of a body of the golf club head and at least one first alignment mechanism; assembling the model of the golf club head using the at least one first alignment mechanism of each of the two or more portions of the model to align the two or more portions of the model, the model comprises the body of the golf club head and a joined alignment mechanism, the joint alignment mechanism comprises the at least one first alignment mechanism of each of the two or more portions of the model; using the model of the golf club head to create a cast for the golf club head; removing the model of the golf club head from the cast; and using the cast of the golf club head to create the golf club head with the joined alignment mechanism; and removing the joined alignment mechanism from the golf club he

Abstract: A lightweight metal mold having a necessary hardness is realized. A plurality of bar-shaped members formed of an evaporative material and a plurality of connecting members formed of an evaporative material are prepared. Each of the connecting members has a spherical shape, and ends of a plurality of the bar-shaped members can be connected to each connecting member. Since a fixing angle of each bar-shaped member with respect to the connecting member can be adjusted freely, a three-dimensional mesh structure having various shapes can be formed. By combining the plurality of bar-shaped members and the plurality of connecting members, an evaporative pattern including the three-dimensional mesh structure can be assembled. By adjusting the shape of the three-dimensional mesh structure, the hardness necessary for the metal mold can be obtained, and the metal mold can be made lighter.

Abstract: A lightweight metal mold having a necessary hardness is realized. A plurality of bar-shaped members formed of an evaporative material and a plurality of connecting members formed of an evaporative material are prepared. Each of the connecting members has a spherical shape, and ends of a plurality of the bar-shaped members can be connected to each connecting member. Since a fixing angle of each bar-shaped member with respect to the connecting member can be adjusted freely, a three-dimensional mesh structure having various shapes can be formed. By combining the plurality of bar-shaped members and the plurality of connecting members, an evaporative pattern including the three-dimensional mesh structure can be assembled. By adjusting the shape of the three-dimensional mesh structure, the hardness necessary for the metal mold can be obtained, and the metal mold can be made lighter.

Abstract: An evaporative pattern having a high strength is provided. An evaporative pattern 102 is a pattern for an evaporative casting. In the evaporative pattern 102, a reinforcing member 30 which is made of a non-evaporative material that does not evaporate by heat of a molten metal is embedded in a joint 114 which is made of an evaporative material that evaporates by the heat of the molten metal. The evaporative material is typically foam polystyrene. The strength of the foam polystyrene is low. Since the reinforcing member which is made of a material having strength higher than that of the evaporative material is embedded in the evaporative pattern 102 which is made of the foam polystyrene, the strength of the evaporative pattern 102 improves.

Abstract: A method of manufacture of a wax model of an annular bladed turbomachine stator assembly includes in succession the positioning, in a mould, of a core intended to form the impression of a cavity of a blade of the assembly, the injection of a wax in the mould, and the removal of the wax model fitted with the core from the mould. The core is manufactured in metal and is positioned such that its radially internal end is housed in the portion of the mould defining the blade including the cavity, away from the radially internal end of this portion of the mould.

Abstract: An investment casting process wherein the wax pattern tool (44) is flexible to facilitate removal of the tool from the cast wax pattern (52) even when the cast shape would otherwise require multiple pull planes. The flexible tool may include a flexible insert (42) precisely indexed to a surrounding coffin mold (40), and thereby to an enclosed ceramic core (10). Positioning pins (106) may extend from the flexible tool to make compliant contact against the core prior to a wax injection step. The surface of the resulting wax pattern may contain an engineered topography (36) replicated through the flexible surface from a master tool (12). The flexible tool may encase thermally conductive or magnetic particles (92), or other active device (96) such as a sensor or vibrator which is operable during wax injection.

Abstract: A gas turbine engine component has a leading edge and a trailing edge and a pressure side and a suction side. The pressure side and suction side extend between the leading edge and trailing edge. One or more cooling passageways extend through the airfoil and comprise a trunk extending from an inlet. At the inlet, there is an additional passageway adjacent the trunk and having at least one edge recessed relative to the trunk.

Abstract: A method of manufacturing a replica diffraction grating includes the steps of: forming a metal thin film on a grating surface of a master diffraction grating, adhering a replica substrate to the metal thin film via an adhesive, and removing the replica substrate so that the metal thin film in a reverse state is adhered on the replica substrate. In the method, before forming the metal thin film on the grating surface of the master diffraction grating, the grating surface is coated with a fluorine surface treating agent as a release agent. Then, the metal thin film is formed with vacuum vapor deposition.

Abstract: A lightweight part and process and device of making the same, the lightweight part including an inner core including a metal foam. A dense core surface layer is metallically joined to the inner core. An outer wall includes an essentially pore-free cast metal layer that is at least one of positively engaged with the dense core surface layer and surrounding the inner core, and metallically joined to the dense core surface layer and surrounding the inner core. The process includes creating a core part by forming the dense core surface layer, forming the inner core of a metal foam, and metallically joining together the inner core and the dense core surface layer. The process further includes creating a finished part by positioning the core part in a casting mold, feeding a melt material into the casting mold, and allowing the melt material to solidify so as to form the outer wall.

Abstract: A fugitive pattern of an article to be investment cast wherein the pattern includes a plurality of locator embossments disposed in an array to provide a datum reference system by which the pattern can be held and positioned by a manipulator, such as for example a gripper device to a computer controlled robotic device, for assembly with another component of the pattern assembly. The datum embossments are located on a portion of the pattern that will be removed from the final metallic casting made to replicate the pattern. The casting includes integral cast datum embossments thereon by which the casting can be held and positioned.

Abstract: A crankshaft casting pattern insert 10 which includes selectively adjustable portions 14, 16, which respectively correspond the front and rear main bearing journal portions of the crankshaft. Each adjustable portion 14, 16 includes a removable insert or member 18, a key member 20, several “vertical” spacers 22, several “lateral” spacers 24, and a fastener 26. Adjustable portions 14, 16 allow the pattern 10 to be selectively modified in shape, effective to compensate for pattern wear and to allow multiple crankshafts to be produced which have a substantially similar balance capability. Pattern 10 may also include several validation pads or points 50 which allow the produced crankshafts to be measured with improved accuracy.

Abstract: The coated pattern is formed from a consumable pattern, preferably polystyrene, and is adapted to be decomposed and replaced by molten metal to form a casting. The improved coating is the dried residue of an aqueous coating formed from water, refractory particles, and from between about 25 wt-% and 75 wt-% organic polymer on a non-volatile solids basis (i.e., dry film basis). Lustrous carbon is reduced when casting iron.

Abstract: A pattern from which cast nodes can be produced, the pattern including a central ring or disc against which one or more stubs abut at selected stations to enable nodes of differing annular geometries and/or stub diameter to be produced from the same pattern.

Abstract: This invention includes a method, a casting pattern, and an apparatus directed to gasifying residue during metal casting. The method for metal casting includes using a casting pattern that includes an additive that can react with a residue formed as the casting pattern degrades during casting. The casting pattern includes an additive that can react with a residue formed as a result of degradation of the casting pattern during casting. The metal casting apparatus includes a casting pattern having an additive that can react with a residue formed as the casting pattern degrades during casting, and a casting medium in which the casting pattern is at least partially immersed.

Abstract: Electronic parts such as an inductor of improved connectivity between magnetic and conductive materials made by sintering the magnetic material under a condition where no accumulation is developed, by forming a hollow-core of a shape different from an external shape of said conductive material through said magnetic material to be molded by an extrusion-molding means while inserting said magnetic material into said hollow-core, or by providing an erasable means to be removed by a heat treatment in said conductive material and conducting extrusion molding so as to embed said conductive material into said magnetic material, said erasable means being removed during a sintering treatment to form a space between said conductive material and said magnetic material, and a method for making same.

Abstract: Disclosed herein is a multi-piece cylinder head lost foam pattern assembly comprising a first piece having a planar valve seat surface extending at an angle other than 90.degree.

Abstract: A method for casting a housing and insert assembly including a housing and a cast-in-place insert. The casting method comprises the steps of providing a prefabricated insert, surrounding the insert with an evaporable foam pattern to form a pattern and insert assembly, and utilizing the pattern and insert assembly in a lost foam casting process wherein the pattern is replaced by a material to form the housing and insert assembly.

Abstract: A lost foam pattern assembly comprising a crankcase section including first and second mounting surfaces, a right cylinder section which is fixed to the first mounting surface and which includes a primary locator, a left cylinder section which is fixed to the second mounting surface and which includes a primary locator, a transfer passage having an upper end located in the right cylinder section, and a transfer passage having an upper end located in the left cylinder section.

Abstract: The shape-dictating surfaces of the pattern are constituted by a thin self-supporting shell (4 & 5) of photocured polymer. The shell is produced by a laser controlled by a computer with reference to a design drawing. The inside of the shell is packed full of low melting-point modeling compound. The areas (6 & 7) of the pattern that do not dictate shape are demarcated by the low melting-point modeling compound.

Abstract: A cast tubular structure including an integral hose connection element formed thereon is produced by lost foam casting wherein a circular socket seat is formed on a pattern for a body portion of the cast tubular structure and a cylindrical pattern for the integral hose connection element is formed by a mold without vent openings on the mold surface in the area of the cylindrical pattern corresponding to the hose sealing surface of the cast tubular structure. The pattern sections are joined with the pattern section for the hose connection element sealing within the circular socket seal formed in the body portion of the cast structure.

Abstract: Disclosed herein is a lost foam pattern assembly comprising a crankcase section including first and second planar surfaces intersecting at an angle defined therebetween, a port cylinder section fixed to the first surface of the crankcase section, and a starboard cylinder section fixed to the second surface of the crankcase section, which port and starboard cylinder sections are fixed to each other along a glue face located in a plane bisecting the angle.

Abstract: A pattern for use in casting a rotatable shaft, such as a crankshaft for an internal combustion engine. The pattern includes an evaporable foam pattern section composed of a material such as polystyrene and having a configuration conforming to the crankshaft to be cast. The evaporable foam pattern section includes a plurality of cranks connected by bearing areas, and tubular metal inserts formed of bearing quality steel are disposed around each bearing area and around the pin areas of the cranks. In the casting process, the pattern is placed in a mold and surrounded with a finely divided material such as sand. When molten ferrous metal is fed into contact with the pattern, the pattern will vaporize with the vapor passing into the interstices of the sand while the molten ferrous metal will occupy the void created by the vaporized foam to produce a cast crankshaft having bearing quality steel inserts at the bearing and pin areas.

Abstract: An evaporable foam pattern assembly for casting a housing for a rotary engine. The pattern assembly includes a central rotor chamber pattern section and a pair of end pattern sections which, in the cast engine, are mounted on either side of the central section. The cental pattern section is provided with a central chamber of epitrochoidal shape and the end sections are each formed with a central opening. The outer portion of each central opening is cylindrical in shape, while the inner portion is elliptical and separated from the outer portion by a relief groove. Each end pattern section is provided with an air passage that communicates through the relief groove with the elliptical opening, so that in the assembled cast engine, air introduced into the passage of one of the end sections flows into the rotor chamber of the central section and is discharged from the other end section.

Abstract: A foam pattern assembly for use in forming an engine block in a lost foam casting process, the pattern assembly comprising a base portion including a generally planar front mounting surface having therein a plurality of crankcase-defining cavities and a plurality of intake ports, and a rear mounting surface spaced from the front mounting surface, the base portion partially defining a plurality of transfer passages and a plurality of air intake passages each communicating between a respective one of the intake ports and a respective one of the transfer passages, and a cylinder portion including a generally planar front mounting surface mating with the rear mounting surface on the base portion, the cylinder portion partially defining the air intake passage and partially defining a plurality of cylinder bores each communcating with a respective one of the transfer passages.

Abstract: A lost foam pattern for an engine block includes a cylinder and an axially extending transfer passage defined by spaced side walls and an inner wall which is outwardly convex.

Abstract: An evaporable foam pattern for producing a cast metal head for a multiple cylinder engine. The assembled pattern includes an elongated block of evaporable foam material having opposed inner and outer faces. A plurality of generally circular head recesses are formed in the inner face and define the cylinder heads in the metal casting. The block is also formed with an internal passage including a group of annular chambers that surround the head recesses and channels interconnect adjacent chambers. The block also has an inlet which communicates with one end of the internal passage and an outlet that communicates with the opposite end of the passage. The pattern is composed of a pair of longitudinal pattern sections having abutted edges that are joined together by an adhesive. The heads, as well as the inlet and outlet, are located in one of the pattern sections, while the two sections in combination define the internal passage.

Abstract: The forming of a wax or sacrificial pattern for investment castings in which the interior ceramic reinforced passageway forming elements are reinforced with a metallic wire, and sheathed in a quartz material is disclosed. Thereafter the wire and quartz serve as a reinforced core around which the ceramic is molded to the configuration of the passageway, and in addition containing the positioning elements for mating engagement with the wax injection die at each end of the passage forming part. The method of forming the pattern for injection molding involves the steps of first determining the passage locations, and thereafter forming a reinforced passage ceramic forming member to be positioned interiorly of the pattern. The wax injection die is formed with mating elements to support the ceramic passage forming members. Thereafter the mold is filled with sequential layers of ceramic, and fired.

Abstract: An evaporable foam pattern for use in casting a metal part, such as an engine block. The pattern includes a first evapoable foam section having an outer peripheral rim and an internal wall which is spaced from the rim. The pattern also includes a second pattern section having a rim disposed in abutting engagement with the rim of the first section and having an internal wall spaced from the rim and disposed in abutting engagement with the internal wall of the first section. A third pattern section is disposed outwardly of said second section and has a rim disposed in abutting engagement with the rim of the second section. A layer of adhesive or glue is disposed between the abutting rims and between the abutting internal walls.

Abstract: A metal casing pattern of expanded thermoplastics material such as polystyrene or polymethyl methacrylate has a filter comprising a porous ceramic body, such as a body having pores extending from one face to another face or a foam structure, incorporated therein.

Abstract: A core assembly is formed by molding a destructible plastic form in abutting relation to a rigid bonded core. The core assembly can be used for casting large or long and thin castings. The rigid bonded core reinforces the plastic form against flexural and torsional forces as well as forces within the plastic tending to change the dimensional configuration of the plastic form.

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: A process for production of castings is provided employing patterns combining gasifiable pattern parts, for the creation of nonconforming contours, with reusable pattern parts. After molding, only the reusable pattern parts are removed from the mold, while the gasifiable pattern parts are destroyed during casting.

Abstract: A foam mold pattern assembly comprising a pattern having opposite first and second ends, a first projection connected to the pattern for facilitating suspension of the foam mold pattern assembly with the first end facing generally upwardly, and a second projection connected to the pattern for facilitating suspension of the foam mold pattern assembly with the second end facing generally upwardly.

Abstract: A method of fabricating a foam mold pattern for forming an air cooled cylinder head in a lost foam casting process, the cylinder head including a cooling fin, the method comprising the steps of: fabricating a foam mold pattern fin portion including a cooling fin, fabricating a foam mold pattern main portion, and attaching the fin portion to the main portion.

Abstract: The mold body contains a cavity and at least one vent passage for venting gas from the cavity through the body. The vent passage has a portion of predetermined regular shape extending part-way through the cavity wall defining at one end an inlet portion opening into a portion of the cavity with a substantially greater resistance than the cavity to penetration therein of casting material. The vent passage further has an outlet portion formed by an irregular crack in the mold body extending from an inner end exposed to the inlet portion through the mold body, the crack having one of its transverse cross-section dimensions short enough to prevent leakage of casting material therethrough. The mold is made by forming a partially bonded ceramic material containing a casting cavity and incorporating in a wall of the cavity a vent pattern of a shape to mold the portion of predetermined regular shape of the vent passage.

Abstract: The pattern assembly is comprised of: (a) mating first and second clamshell-shaped foam members, the first and second foam members meeting along exteriorly exposed joint margins defined by mateable surfaces extending along opposite sides of each of the members; (b) at least one other foam member nestable totally within the mated assembly of the first and second members and nestable without joint margins exposed to the exterior of the mated assembly; (c) surfaces enclosed within the mated assembly for piloting the first, second and other member into mating relationship; and (d) adhesive material bonding the first and other members together and bonding the second member to the assembly of the first and other member.

Abstract: The drag pattern and the cope pattern for a standard AAR coupler yoke are each mounted on a pattern plate to form an oblique angle of about 1.degree. between the mounting surface of the pattern plate and a plane parallel to a longitudinal center plane of the pattern. The patterns each include core print surfaces for establishing the position of one unitary core which is used in a sand mold to form surfaces in the coupler yoke at the front end portion thereof. The drag pattern includes pattern surfaces to mold sand to form the surfaces surrounding the draft gear pocket on the upper and lower straps and the rear draft gear seat at the rear end portion of the yoke. The draft gear seat is generally planar and perpendicular with each inside wall of top and bottom straps.

Abstract: A vaporizable pattern for casting reduced porosity metal by a lost foam process is coated with a thermally insulative, predominantly refractory particulate layer comprising polymeric particles. During metal casting, the refractory particles insulate the polymeric particles to delay vaporization, whereupon pattern decomposition vapors build up and slow metal replacement of the pattern to reduce vapor-entrapping turbulence. Subsequent vaporization of the polymeric particles produces pores in the residual refractory coating wherethrough pattern decomposition vapors readily vent to avoid entrapment in the metal.

Abstract: A vaporizable pattern for casting reduced porosity metal by a lost foam process is coated first with a thermally insulative, refractory layer characterized by a relatively high gas permeability and thereafter with a vaporizable polymeric layer characterized by a relatively low gas permeability. During metal casting, the refractory layer insulates the polymeric layer to delay vaporization, whereupon the low permeability causes pattern decomposition vapors to build up and slow metal replacement of the pattern to reduce vapor-entrapping turbulence. After vaporization of the polymeric layer, the vapors readily vent through the high permeability, refractory layer to avoid entrapment in the metal.

Abstract: Process for making a multiple unit fixed prosthesis. A conventionally prepared wax bridge is separated into a plurality of segments, a plurality of brace members are partially interconnected between the segments, and an anchoring member having the general configuration of the wax bridge is prepared for attachment to the segmented bridge by first securing a different support member to each pontic and coping of the bridge and by temporarily securing the anchoring member to a preselected one of the pontics or copings. All of the support members are then permanently secured to the anchoring member by an adhesive that does not introduce distortion into the bridge as it hardens.

Abstract: A pattern plate adapted to support a pattern having a plate body with gage blocks to insure uniform body thickness and a plurality of lug and recess sets for forming a series of pockets and bosses in the cope and drag sections of a sand mold. The lug and recess sets are arranged in end-to-end or chain like arrangement adjacent the ends and sides of the body. Each lug and recess set has a pair of arcuate cavities open to opposite sides of the body and a pair of oppositely directed arcuate lugs. Each lug has an arcuate pad projected outwardly along its crown to form a well in the bottom or top of the pockets in the molds to accommodate loose foreign particles, as sand. In one form of the invention two pattern plates are secured together in a side by side relation to form a match plate pattern assembly. The pads on the lugs space the plate bodies from each other to provide a venting passage between the bodies.

Abstract: A wax former and runner are moulded with complementary stud and socket members included in the respective moulds. The former and runner are then assembled simply by pressing stud into socket, thus avoiding loss of dimensional accuracy which would have occurred, had interface melting been employed.

Abstract: A flexible pattern for forming casting molds can be withdrawn from the mold, without need of partitioning and reassembling, and includes a pattern member made by coupling a plurality of outer plates, having a configuration corresponding to a desired predesigned casting, by means of joint members, which are freely removable, and an airtight bag installed in the inner periphery of the pattern member. The pattern member and the airtight bag are united in a single body.

Abstract: A method is presented to make an investment casting pattern of a rotatable turbine wheel or a stationary turbine nozzle wheel having one continuous and regular series of blades extending around its periphery with a uniform pitch between blades and in which all such blades are bent in one circumferential direction and adjacent blades overlap each other in a circumferential direction so that the wheel pattern cannot be made in a simple two part mold separating at right angles to a parting line. The method comprises separately forming two wheel pattern portions of the same diameter as the finished turbine wheel pattern, each having a series of continuous and regular blades around its periphery with a uniform pitch between the blades which is exactly twice the pitch of the blades in the finished wheel pattern. In such a pattern wheel portion the adjacent blades do not overlap each other.

Abstract: A casting-marking apparatus is adapted for incorporation in a permanent foundry pattern of the type used to produce sand molds for metal casting. The apparatus carries a marking that is impressed in the sand old and subsequently reproduced on a casting. The apparatus is designed and constructed so that the marking that it carries can be altered from a station remote from the pattern. In the apparatus, the alterable marking is carried by a marking body that is rotated by an air actuated piston.

Abstract: The drag pattern for a standard AAR coupler is modified to increase the thickness of the bottom wall of a coupler casting forwardly and rearwardly of a plane containing the horn line. The increased thickness is achieved by forming a substantially planar bottom wall surface for a distance of at least two inches at either side of a plane containing the horn line. Head and shank pattern parts are interchangeable and releasably secured onto a pattern plate for molding foundry sand in the drag portion of a foundry mold to produce E, E/F and F-types of coupler castings.