Abstract: A method for producing a molded part for use in a casting method may involve an additive manufacturing process. The method may also include introducing at least one relief joint into the molded part during production in order to prevent or reduce tensile stresses in the molded part.

Abstract: A blade (30?) for a gas turbine has an airfoil (31) and a blade root (32) for mounting the blade (30) on a rotor shaft of the gas turbine. The airfoil (31) is provided with cooling channels (33, 35) in the interior thereof, which cooling channels (33, 35) preferably extend along the longitudinal direction and can be supplied with cooling air (45) through cooling air supply passages (40-43) within the blade root (32). The blade root (32) includes a blade channel (40) running transversely through the blade root (32) and is connected to the cooling channels (33, 35), and an insert (41) is inserted into the blade channel (40) for determining the final configuration and characteristics of the connections between the blade channel (40) and the cooling channels (33, 35).

Abstract: The invention relates to a casting tool for producing workpieces from light metal alloys. The system includes a positioning element, a core part, a first mold part structured to carry the positioning element and be movable toward the core part, and a core part support structured to support the core part. The system also includes at least one stop structured to limit movement of the front mold part toward the core part and to allow the positioning element to be introduced into the core part, whereby the positioning element holds the core part in a predetermined position for casting.

Abstract: A casting includes a wall thickness check feature for measuring thickness of a wall second aside an in-wall cooling passageway. The thickness is determined by observing the existence and/or size of an opening formed by the feature. The casting is cast from a pattern including portions forming the feature. To manufacture the pattern, a pattern-forming die is assembled with a ceramic feedcore and a refractory metal core (RMC). The assembling leaves an inlet portion of the RMC engaged to the ceramic feedcore and leaves an outlet portion of the RMC engaged to the die. A pattern-forming material is molded in the die at least partially over the ceramic feedcore and RMC. The die is disengaged from the pattern-forming material. The assembling engages a stepped projection of the RMC with a mating surface of the die.

Abstract: A method for forming an investment casting core comprises cutting a patterned core precursor from refractory metal-based sheet. The cutting forms recast along the cuts. An oxide is grown on non-recast areas. The recast is substantially chemically removed but substantially leaving the oxide. The core precursor may then be shaped.

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: The present invention is a method for casting a part having a complex shape or having a complex shape thereon. The method includes providing a pattern and securing at least one core to the pattern. A conformable material is located about the pattern and the core to create a complementary shape to the pattern and core in the conformable material. The pattern is removed and the core is left behind in the conformable material. The core leaves space, or an empty form, for a negative draw that cannot be formed in known casting methods. A mold is located adjacent the shaped, conformable material. A hardenable material is located between the mold and the shaped, conformable material and into the core. The hardenable material is allowed to harden and then it is removed. A cast part having a complex shape, or having a complex shape integrally formed with the part, results.

Abstract: The invention provides equipment for molding castings in a mold having at least one sand core (Na1), in which the positioning of the or each core is obtained by the core co-operating with an element (S) of the mold, in particular a metal mold element. This equipment is remarkable in that the or each core possesses an insert (I) secured to the core while making said core and via which said core is suitable for co-operating with the mold element in question. The invention also provides an associated method of positioning cores. The invention is particularly applicable to improving the positioning of admission pipes in light alloy cylinder heads for engines.

Abstract: The invention relates to a method for producing a cooled cast part for a thermal turbo machine by using a known casting process. Between a wax model of the cast part and a ceramic core, a wax seal is applied by hand above a step, only on an additional shoulder. The material that is created during the casting process at this point by the shoulder and the wax seal can be ground off without causing rough areas on the step to form. This simplifies the welding or soldering of a cooling plate to the step.

Abstract: A casting mold includes a cavity formed therein, and an auxiliary mold projecting into the cavity. The auxiliary mold forms a concave portion in a cast product, and it exhibits a thermal expansion coefficient being more than a thermal expansion coefficient exhibited by a molten metal to be charged into the cavity. Hence, the auxiliary mold greatly expands thermally during casting, and it keeps the expanded state during the solidification of the molten metal. Accordingly, the casting mold can prevent the casting defects resulting from the shrinkage cavities from arising in the resulting cast products. All in all, the casting mold can obviate to give the auxiliary mold a tapered configuration, and it can reduce the after-casting machining allowance to be provided in the resulting concave portion.

Abstract: In an investment casting process including the known steps of injecting a molten wax into a die, allowing the wax to solidify, removing the die, investing the wax with ceramic, firing the ceramic and removing the wax so as to provide a ceramic mould, and casting a molten material into the mould, and apparatus including a ceramic core the shape and size of the cavity to be provided in the blade, a removable wax impression die surrounding and spaced from the core member so that the space between the die and the core member is the shape and size of the blade, there is provided a number of platinum chaplets adapted and arranged to support and locate the core in relation to the ceramic mould by point contact abutment with an adjacent mould surface.

Abstract: A core assembly is formed by molding a destructible plastic form around at least one insert and optionally around a non-destructible core. The core assembly can be used, for example, for casting engine cylinder heads having valve seat inserts integral therewith. The plastic form retains and supports the inserts until the precise time the plastic is replaced by the molten metal.

Abstract: An improved core is adapted to extend axially through the central portion of a mold cavity in which an airfoil or other article is formed. The core is used to form cooling passages as the airfoil is cast in the mold cavity. The core has an elongated cantilevered center section which is disposed within a main or base section. A metallic pin member extends from a free end portion of the cantilevered center section of the core to the main section of the core to hold the free end portion of the cantilevered center section against movement relative to the main section.

Abstract: A method and a support structure for use in casting metal articles which define at least one internal passage and wherein the support structure is associated with a core or cores employed during the casting operation. In that operation, the cores are confined within a disposable pattern, and a ceramic mold is formed around the pattern. When the pattern material is removed, a mold cavity is provided with the core positioned in the cavity to form the desired opening in the cast article. The support structure for the core comprises a member positioned between the core surface and the opposing mold surface. This member is encompassed by the pattern material when the pattern material is formed around the core. During the subsequent removal of the pattern material and also during curing of the ceramic mold, the support member serves to hold the core in place so that the dimension of the casting wall surrounding the internal passage can be precisely maintained.

Abstract: A core assembly for use in the casting of molten metal is formed by fabricating a first core, molding a plastic layer around the first core, and molding a second core around the plastic layer. The plastic layer is interlocked with an irregular outer surface of the first core, and the second core is interlocked with an irregular outer surface of the plastic layer. The plastic layer is then dissolved with a suitable solvent prior to placing the core assembly into a mold and molten iron being poured.

Abstract: The method of casting a plate type recuperative heat exchange envelope that encloses a hollow space therein in a single casting operation. A sand core with a heat sensitive binder therein defines the hollow space within the envelope. The sand core is supported by end extensions and lateral protuberances which rest on the sides of a sand mold to provide a space therebetween that is subsequently filled with molten metal to comprise an envelope casting. Lateral openings through the envelope casting produced by the lateral protuberances and end openings produced by the end extensions provide passageways for venting gases produced within the sand core during the casting operation, and after completion of the casting operation the same openings in the envelope assist in the removal of the sand core therefrom. The lateral openings are subsequently plugged while the end openings are maintained open to direct the flow of fluid therethrough.

Abstract: A core assembly is formed by fabricating a first core, molding a destructible plastic layer around the first core, and molding a second core around the plastic layer. The plastic layer is interlocked wth an irregular outer surface of the first core, and the second core is interlocked with an irregular outer surface of the plastic layer. The core assembly can be used for casting engine cylinder heads to eliminate the need for gluing cores together and the accompanying formation of fins within fluid conducting passages.

Abstract: A core assembly is formed by fabricating a first core, molding a destructible plastic layer around the first core, and molding a second core around the plastic layer. The plastic layer is interlocked .[.wth.]. .Iadd.with .Iaddend.an irregular outer surface of the first core, and the second core is interlocked with an irregular outer surface of the plastic layer. The core assembly can be used for casting engine cylinder heads to eliminate the need for gluing cores together and the accompanying formation of fins within fluid conducting passages.