Abstract: A lost foam casting pattern that is constructed of a plastic filament, a foaming agent, and a coating. The lost foam casting pattern is printable on a 3-D printer. A 3-D printable material for the creation of a lost foam casting pattern is also disclosed where the material includes 95.0% to 99.75% by weight of a plastic filament combined with 0.25% to 5.00% by weight of a foaming agent. A method for preparing a lost foam casting pattern using the 3-D printable material is further described.

Abstract: A turbine shroud assembly for a gas turbine engine includes a shroud wall extending circumferentially partway around a central reference axis to define a gas path of the gas turbine engine. An attachment feature extends radially from the shroud wall. A foam is located at least on the shroud wall.

Abstract: A high heat-absorption casting core for manufacturing a cast component includes a core body. The core body has at least a portion thereof defined by metal powder. The metal powder is configured to absorb heat energy from the cast component during cooling of the component and solidification thereof. The core body may be additionally defined by a sand fraction in contact with the metal powder fraction. A system and a method for manufacturing a cast component using the high heat-absorption casting core are also envisioned.

Abstract: A method for forming a metallic structure having a secondary component includes positioning the secondary component on a main formation surface of a main tool, the main formation surface corresponding to a desired shape of a first layer of material. The method also includes depositing a layer of material on the secondary component and the main formation surface using a cold-spray technique such that the layer of material bonds to the secondary component. The method also includes removing the layer of material and the secondary component to form the metallic structure.

Abstract: Methods for forming channels within a substrate include molding a sacrificial component directly into the substrate and igniting the sacrificial component to deflagrate of the sacrificial component and form a channel in the substrate. The sacrificial component can include oxidizing agents such as chlorates, perchlorates, nitrates, dichromates, nitramides, and/or sulfates imbedded in a polymeric matrix, and the oxidizing agents can be 30 wt. % to 80 wt. % of the sacrificial component. The sacrificial component can further include one or more of unoxidized metal powder fuels, flammable gas-filled polymeric bubbles, one or more metallocenes and/or one or more metal oxide particles, one or more polymers with nitroester, nitro, azido, and/or nitramine functional groups, one or more burn rate suppressants such as oxamide, ammonium sulphate, calcium carbonate, calcium phosphate, and ammonium chloride, and non-combustible hollow bubbles and/or inert particles.

Abstract: A machine includes a section that defines a target vibrational mode to dampen and a nanocellular foam damper that includes interconnected ligaments in a cellular structure. The interconnected ligaments have an average ligament size defined with respect to a vibrational loss modulus of the nanocellular foam damper and the target vibrational mode. Also disclosed is a method of damping vibration.

Abstract: Methods and systems for creating a mold for a cast memorialization product are described herein. In a process for creating a mold, a three-dimensional (3D) model of a product design is generated. The product design includes customized features for a memorialization product. A mold design is generated based upon the 3D model of the product design. Printing instructions for creating the mold are generated and accessed by a processing device. The mold is created according to the printing instructions. A product, such as a bronze memorialization product, can be cast using the mold.

Abstract: A hybrid method of additive manufacturing is provided. The method includes providing a powder material and fusing, by a first heat source, a portion of the powder material to form a three-dimensional structure. The three-dimensional structure can define a fill region at least partially filled with the powder material. The method further includes fusing, by a second heat source, the powder material in the fill region. Fusing the powder material in the fill region can solidify the powder material in the fill region and fuse the powder material to the three-dimensional structure for forming a solid object.

Abstract: Disclosed are a method of casting heterogeneous materials and a casting produced manufactured by the same. The method may include disposing a lost foam on a cavity of a mold as the cavity being formed in a shape corresponding to a shape of a casting product; injecting a first molten metal through a low-pressure molten metal ingate formed in the mold to form a low-pressure casting portion of the casting product; and injecting a second molten metal through a gravity molten metal ingate formed in the mold to form a gravity casting portion of the casting product.

Abstract: An investment casting model for the creation of a mold for investment casting of a plurality of objects, the investment casting model being realized in solidifiable resin, and includes: a base defining a Z axis; a plurality of wire-like elements all extending from the base, the wire-like elements intersecting each other to form a plurality of simple closed curves, which form a net around the Z axis. At least two of the simple closed curves of the plurality are identical to each other and the net includes: at least a first and a second sets of simple closed curves, each set forming a net sub-structure around the Z axis, the second set being adjacent to the first set along the Z axis; a plurality of object models; and a plurality of connecting branches joining the plurality of object models to the wire-like elements forming the net.

Abstract: Various embodiments of making an investment casting mold are disclosed. The method includes coating a sacrificial pattern with a prime layer that includes a first refractory slurry and a first refractory stucco; at least partially hardening the prime layer; and coating the prime layer with an intermediate layer that includes a second refractory slurry and a second refractory stucco. The method further includes at least partially hardening the intermediate layer; coating the intermediate layer with a first backup layer that includes a first thixotropic agent, the first thixotropic agent including a first polymer emulsion; coating the first backup layer with a second backup layer that includes a second thixotropic agent, the second thixotropic agent including a second polymer emulsion; and at least partially hardening the first backup layer and the second backup layer.

Abstract: A method of manufacturing a heat shield panel assembly is provided. The method including: injecting melted wax into a negative cavity of a heat shield panel, the heat shield panel including one or more orifices; allowing the wax to solidify to form a positive pattern of the heat shield panel; removing the positive pattern from the negative cavity; coating the positive pattern with a ceramic; melting the positive pattern away from the ceramic, the ceramic having a cavity forming a second negative cavity of the heat shield panel; pouring melted metal into the cavity; allowing metal in the cavity to solidify to form the heat shield panel; removing the ceramic from the heat shield panel; and forming each of one or more threaded studs separately from the heat shield panel, each of the one or more threaded studs including a stud portion and a thread portion simultaneously formed.

Abstract: A method of fabricating a finished part includes generating or creating a master pattern using an additive manufacturing process, and the master pattern corresponds in shape to the finished part. A shell is created by applying one or more layers of one or more coating materials to the master pattern. The master pattern is then dissolved while the master pattern is in the shell to create a cavity in the shell that corresponds in shape to the finished part. A molten material is then poured into the cavity of the shell. The molten metal is allowed to cool and to harden and/or to reach a determined temperature such that the molten metal becomes the finished part. The shell is then removed from around the finished part.

Abstract: A golf club and golf club head having a high static loft angle, low forward center of gravity, and enhanced z-axis gear effect via a large roll radius and/or tightly controlled moment of inertia about the CG x-axis, Ixx, associated with upward and downward twisting of the club head.

Abstract: A machine includes a section that defines a target vibrational mode to dampen and a nanocellular foam damper that includes interconnected ligaments in a cellular structure. The interconnected ligaments have an average ligament size defined with respect to a vibrational loss modulus of the nanocellular foam damper and the target vibrational mode. Also disclosed is a method of damping vibration.

Abstract: A skeletal composite material includes an internal skeleton structure surrounded by a matrix material. The skeleton structure and the matrix are made of different materials having different properties. It should be appreciated that the skeleton structure and the matrix can be made of any suitable material including metal, ceramic, carbon, polymers, or combinations of these materials. Preferably, the skeleton structure and/or the matrix are made primarily of metal or ceramic. The skeletal composite material can be made by filling a skeleton structure with powder, compacting the skeleton structure and powder to form a preform, and consolidating the preform to form the skeletal composite material.

Abstract: An intake-port core includes a body part having the same outer shape as that of the intake port, a port-injector part having the same outer shape as that of a port-injector insertion part, and an extending part. A cooling-water flow-passage core includes a water-jacket core having the same outer shape as that of a water jacket. The intake-port core is inserted from the extending part thereof into the water-jacket core so as to join the cooling-water flow-passage core to the intake-port core. Thereafter, a core print part that is a separate body from the intake-port core is joined to the intake-port core.

Abstract: A lost wax cast vapor chamber device is provided. Once a mesh is produced, a meltable core is formed from a meltable core material with the mesh positioned at least partially inside the core. Over the meltable core a metallic layer is formed, at least partially surrounding the meltable core. A chamber formed by the metallic layer is exposed by melting the meltable core to cause it to be removed from an internal void of the chamber, the internal void encapsulating the mesh. The melted material from the meltable core flows out an opening on at least one surface of the chamber. Subsequently, the internal void is filled at least partially with a working fluid and the opening is closed. The mesh supports the surfaces of the chamber against deformation under the vacuum of the internal void. Movement of working fluid by capillary action is facilitated by the mesh.

Abstract: A mold assembly for rotating electrical machines housings, the mold having part of the cooling duct geometry on its side portion and another portion on the center mold, in order to eliminate the requirement of casting plugs. A rotating electrical machine housing manufactured from the mold assembly.

Abstract: A method for forming a metallic structure having a non-linear aperture includes providing a main tool having a formation surface corresponding to a desired structure shape of the metallic structure. The method also includes attaching a removable tool having a shape corresponding to a desired aperture shape of the non-linear aperture to the main tool. The method also includes depositing a layer of material on the formation surface using a cold-spray technique. The method also includes removing the removable tool from the layer of material such that the layer of material defines the non-linear aperture.

Abstract: An investment mold includes a mold cavity and a refractory investment wall that bounds at least a portion of the mold cavity. At least a portion of the refractory investment wall includes a plurality of fugitive beads. The fugitive beads can be sacrificed to provide voids that control the strength of the refractory investment wall such that the wall fractures at the voids during investment casting to alleviate stress on a solidified metal cast in the mold cavity.

Abstract: In the following expression, it is assumed that a thickness of a coating agent applied to a foam pattern [2] is t (mm), a diameter of a hole part [3] is D (mm), and a normal-temperature transverse strength of the dried coating agent is ?c (MPa). At the time of producing a casting provided with a hole having a diameter of 18 mm or smaller and a length of 1 (mm), a coating agent that satisfies the following expression is used when a solidification end time te (sec) at which solidification of a melt ends on a periphery of the hole part [3] is within a time t0 (sec) at which thermal decomposition of the coating agent ends. ?c?{t0/(t0?te)}×(1.

Abstract: A print on-demand color shift material which has high reflection, high saturation color and intrinsic, high impact color-shift produced by thermal printing or laser writing for use, for example in security laminates, tax and excise stamps, machine-readable features and banknote foils, and offering a rainbow of colors with full color shifting, producible in full manufacturing scale.

Abstract: A green metal body includes metal particles and a binder in the shape of an orthodontic bracket and/or base plate. The green metal body is fabricated by being laser-cut with a laser to shape the green metal body into the shape of an orthodontic bracket and/or to carve recesses and/or undercuts into the bonding surface of the bracket. The green metal body is sintered to shrink its volume into a denser and less porous sintered metal body configured to be an orthodontic bracket. The resultant sintered orthodontic bracket includes recesses and/or undercuts in the bonding surface to provide a mechanical aspect when bonded to a tooth.

Abstract: Provided is a casting method using lost foam capable of forming a small highly-finished hole with a diameter of 18 mm or less and a length of 50 mm or more by casting. A casting method using lost foam of the present embodiment includes the steps of embedding, in foundry sand, a casting pattern formed by applying a mold wash with a thickness of 1 mm or more to a surface of the foam pattern, the foam pattern having a hole with a diameter of D (mm); replacing the foam pattern with molten metal by pouring the molten metal into the casting pattern and losing the foam pattern; and forming a casting having a small hole with a diameter of 18 mm or less and a length of 50 mm or more by cooling the molten metal, and the method satisfies the following formulas (0) and (1): 2<D?19.7??Formula (0) ?c??0.36+140/D2??Formula (1) where ?c (MPa) is transverse rupture strength (bending strength) of the mold wash that is heated to decompose resin constituting the mold wash and then returned to room temperature.

Abstract: A heat exchange system for casings of rotary electric machines is described herein. The heat exchange system applied to the rotating electrical machine casing and the machine is equipped with a finned casing comprising a number of fins equipped with a modified profile, each one interleaved with complementary fins, both profiles distributed over the external surface of the casing. The fins have a predominantly continuous profile, supported in parallel along the casing height, and respectively show projections from a guideline, with structures with trapezoidal or rectangular section being interleaved to one another in a front region of the machine.

Abstract: A blade preform includes a strut connecting a plat-form to a blade root portion extending longitudinally in an upstream-downstream direction, an upstream web and a downstream web, which each extend in a direction substantially perpendicular to the longitudinal direction of the blade root and are formed at the upstream and downstream ends of the strut. The upstream and downstream webs connect the upstream and downstream ends of the plat-form to the upstream and downstream ends of the blade root. The blade root extends in a direction perpendicular to the longitudinal direction of the blade root over a distance smaller than that of the upstream and downstream webs and the side edges of each web are extended by walls that converge at the flanks of the blade root.

Abstract: A method to manufacture reticulated metal foam via a dual investment, includes pre-investment of a precursor with a diluted pre-investment ceramic plaster then applying an outer mold to the encapsulated precursor as a shell-mold.

Abstract: A method for making a gas turbine engine ceramic matrix composite airfoil is disclosed. The method includes fabricating an airfoil preform that has a slotted forward end and a continuous trailing end. The slotted forward end of the airfoil preform is coupled to an airfoil core insert. A ceramic matrix composite covering is applied to cover the slots of the airfoil perform. The continuous trailing end of the airfoil preform is removed to expose the slots. A gas turbine engine airfoil is also disclosed.

Abstract: A ceramic mixture is shaped to form a ceramic core having a configuration which corresponds to the configuration of a cavity in an airfoil. The ceramic core is positioned between a plurality of arrays of burners. Flames from the burners burn organic material contained in the ceramic core. During burning of the organic material, the core is upright with a longitudinal central axis of the core in a generally vertical orientation. The ceramic core may be dipped in a ceramic material after having performed the step of burning organic material and prior to additional heat treatment of the ceramic core.

Abstract: Certain exemplary embodiments can provide a system, machine, device, manufacture, and/or composition of matter configured for and/or resulting from, and/or a method for, activities that can comprise and/or relate to, investment casting a product in a mold, the product comprising at least one wall, the mold comprising a core, an inner primary shell, and an outer secondary shell.

Abstract: A method for removing a part from a mold and to a machine for molding the part, the part made of a material having a glass-transition temperature and a melting temperature that is higher than the glass-transition temperature, and which is shaped in the cavity of a mold, includes at least two mold portions defining the shaping cavity therebetween. The mold is at a temperature between the glass-transition temperature and the melting temperature. The method includes opening the mold by spacing apart the mold portions, locally spraying a cooling gas toward the part remaining in a portion of the mold using at least one nozzle, and, after a predetermined time period following the start of spraying the gas, ejecting the part from the portion of the mold, the time period being such that the part reaches a temperature that is lower than the glass-transition temperature thereof.

Abstract: Certain exemplary embodiments can provide a system, machine, device, manufacture, and/or composition of matter configured for and/or resulting from, and/or a method for, activities that can comprise and/or relate to, investment casting a product in a mold, the product comprising at least one wall, the mold comprising a core, an inner primary shell, and an outer secondary shell.

Abstract: A grain starter for use in solidification of molten metallic material forming an article having a directional grain structure and a method for solidifying an article having a directional grain structure with a substantial absence of stray grains. The grain starter comprises a grain-starting material that initiates grain growth in the molten metallic material in a preselected crystallographic direction. The grain-starting material has a melting temperature higher than the metallic material forming the article lest the grain starter be modified by contact with the molten material. The grain starter further includes a feature that modifies heat transfer characteristics of the metallic material in contact with it in order to produce an article having grains oriented in the preselected crystallographic orientation and modifies the profile of the advancing solidification front. The article is substantially free of stray grains not oriented in the preselected crystallographic direction.

Abstract: The disclosure relates generally to mold compositions and methods of molding and the articles so molded. More specifically, the disclosure relates to silicon carbide-containing mold compositions, silicon carbide-containing intrinsic facecoat compositions, and methods for casting titanium-containing articles, and the titanium-containing articles so molded.

Abstract: A method of casting a low alloy steel using a mold is disclosed. The method includes receiving the mold having a foam pattern disposed within a sand casing. The received foam pattern is coated with a permeable refractory coating and is disposed between compacted sand and the sand casing. The method further includes pouring a molten metal comprising a low alloy steel having a carbon content in a range from about 0.1 to about 0.4 percent into the mold so as to vaporize the foam pattern and remove gasification products through the permeable refractory coating, to form a low alloy steel casting. Further, the method includes removing the low alloy steel casting from the mold.

Abstract: The object of the present invention is to provide an embedding material composition for casting that makes it possible to conduct a favorable casting in the case where casting is conducted using a resin pattern that is different from a conventional wax pattern in disappearance temperature and disappearance behaviors through “rapid heating” excellent in treatment efficiency. The present invention relates to an embedding material composition for casting not using a heat-expandable refractory material as a main component, comprising: a binder; and a non-heat-expandable refractory material having an average particle diameter of 5 to 20 ?m as main components, in which a content of the binder is 25 to 40 parts by mass and a content of the non-heat-expandable refractory material is 60 to 75 parts by mass in the case where the total amount of the main components is 100 parts by mass, and the present invention also relates to a casting process using the embedding material composition for casting.

Abstract: Various embodiments include methods and related systems for laser-assisted casting. Some embodiments include a method including: performing laser ablation to a preliminary wax casting model to form a modified wax model including at least one additional feature absent from the wax casting substrate; coating the modified wax model to form a mold shape around the modified wax model; and removing the modified wax model to leave a casting mold including the at least one additional feature.

Abstract: Various embodiments include methods and related systems for laser-assisted casting. Some embodiments include a method including: performing laser ablation to a preliminary wax casting model to form a modified wax model including at least one cooling hole absent from the wax casting substrate; coating the modified wax model to form a mold shape around the modified wax model; and removing the modified wax model to leave a casting mold including the at least one cooling hole.

Abstract: Various embodiments include methods and related systems for laser-assisted casting. Some embodiments include a method including: performing laser ablation to a preliminary wax casting model to form a modified wax model including at least one surface texture element absent from the wax casting substrate; coating the modified wax model to form a mold shape around the modified wax model; and removing the modified wax model to leave a casting mold including the at least one surface texture element.

Abstract: A multi-wall ceramic core for casting an airfoil with one or more internal cooling passages is made by preforming at least one fugitive core insert to have a joint-forming surface with a male and/or female joint feature and then forming at least one fugitive core insert in-situ adjacent and integrally connected and fused to the at least one preformed core insert at the joint-forming surface to form an interlocked, fused joint to form a composite core insert that includes features to form internal passage surfaces in the core when the composite core insert is removed. Another aspect involves preforming first and second fugitive core inserts to have respective joint-forming surfaces with respective snap-fittable joint features and assembling the first and second fugitive core inserts to form a composite core insert by snap fitting the snap-fittable joint features together to form an interlocked joint.

Abstract: The disclosure relates generally to core compositions and methods of molding and the articles so molded. More specifically, the disclosure relates to core compositions and methods for casting hollow titanium-containing articles, and the hollow titanium-containing articles so molded.

Abstract: An evaporative pattern casting method is taught which does not reduce accuracy of an evaporative pattern. The evaporative pattern casting method comprises a part manufacturing process (S2), an assembly process (S4), a sand mold manufacturing process (S6), a molten metal pouring process (S8) and a sand removal process (S12). In the part manufacturing process, the evaporative pattern is manufactured as a plurality of separate parts. In the assembly process, the parts are assembled on a work plane. In the sand mold manufacturing process, the evaporative pattern is covered with sand to form a sand mold without moving the assembled evaporative pattern from the work plane. In the molten metal pouring process, molten metal is poured into the sand mold. In the sand removal process, the sand is removed after the molten metal has solidified.

Abstract: A method of casting a component (42) having convoluted interior passageways (44). A desired three dimensional structure corresponding to a later-formed metal alloy component is formed by stacking a plurality of sheets (18, 20) of a fugitive material. The sheets contain void areas (22) corresponding to a desired interior passageway in the metal alloy component. A ceramic slurry material is cast into the three dimensional structure to form either a ceramic core (34) or a complete ceramic casting vessel (38). If just a ceramic core is formed, a wax pattern is formed around the ceramic core and an exterior ceramic shell (38) is formed around the wax pattern by a dipping process prior to the removal of the fugitive material and wax. An alloy component having the desired interior passageway is cast into the casting vessel after the fugitive material is removed.

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 multi-wall ceramic core for casting an airfoil with one or more internal cooling passages is made by preforming at least one fugitive core insert to have a joint-forming surface with a male and/or female joint feature and then forming at least one fugitive core insert in-situ adjacent and integrally connected and fused to the at least one preformed core insert at the joint-forming surface to form an interlocked, fused joint to form a composite core insert that includes features to form internal passage surfaces in the core when the composite core insert is removed. Another aspect involves preforming first and second fugitive core inserts to have respective joint-forming surfaces with respective snap-fittable joint features and assembling the first and second fugitive core inserts to form a composite core insert by snap fitting the snap-fittable joint features together to form an interlocked joint.

Abstract: A multi-wall ceramic core for casting an airfoil with one or more internal cooling passages is made by preforming at least one fugitive core insert, then forming at least one core insert in-situ adjacent and fused to the at least one preformed core insert by introducing fluid fugitive pattern material into a composite core insert mold whereby the fugitive core inserts are integrally connected as a single composite core insert that includes features to form internal passage surfaces in the core when the composite core insert is removed. The composite core insert is placed in a core molding die cavity, and a fluid ceramic material is introduced into the die cavity to form the ceramic core body incorporating the fugitive composite core insert therein.

Abstract: A multi-wall ceramic core for casting an airfoil with one or more internal cooling passages is made by preforming at least one fugitive core insert, then forming at least one core insert in-situ adjacent and fused to the at least one preformed core insert by introducing fluid fugitive pattern material into a composite core insert mold whereby the fugitive core inserts are integrally connected as a single composite core insert that includes features to form internal passage surfaces in the core when the composite core insert is removed. The composite core insert is placed in a core molding die cavity, and a fluid ceramic material is introduced into the die cavity to form the ceramic core body incorporating the fugitive composite core insert therein.

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 refractory mold is disclosed. The refractory mold includes a fugitive pattern assembly comprising a hollow sprue that comprises a sprue wall disposed about a longitudinal axis; a pattern disposed outwardly of the sprue wall; and an outwardly extending gate attached to and extending between the sprue wall and the pattern, the hollow sprue, pattern and gate each formed from a fugitive material; and a refractory mold formed on and having a mold cavity defined by an outer surface of the fugitive pattern assembly.