Abstract: A method of manufacturing a golf club head with a plurality of stiffening members proximate the face, and particularly solid rods or a plate with one or more cutouts, is disclosed herein. The method includes the steps of preparing a wax of a golf club head body having at least one through-hole, a hollow interior, and at least one receiving pocket, preparing waxes of one or more stiffening members, inserting the wax of the stiffening members into the through-hole and seating its opposite end in the receiving pocket, bonding each of the stiffening members to the body with an adhesive material to form a combined wax mold, and casting a golf club head from the combined wax mold.

Abstract: The present invention relates to a method for the design and manufacture of a dental component with a surface, wherein a 3D model of the dental component is designed by means of a CAD unit and the dental component is manufactured by a CAM unit on the basis of the 3D model.

Abstract: Methods of manufacturing a golf club head with one or more stiffening members proximate the face, and particularly solid rods or a plate with one or more cutouts, is disclosed herein. One method includes the steps of preparing a wax mold of a golf club head including a plate stiffening member with excess material, casting the golf club head, and machining away the excess material. Another method includes the steps of casting a golf club body, providing a plate stiffening member, providing a face component such as a face cup, tack welding the plate stiffening member and the face component to the golf club body, and welding these parts together.

Abstract: A method of manufacturing a golf club head with a plurality of stiffening members proximate the face, and particularly solid rods or a plate with one or more cutouts, is disclosed herein. The method includes the steps of preparing a wax of a golf club head body having at least one through-hole, a hollow interior, and at least one receiving pocket, preparing waxes of one or more stiffening members, inserting the wax of the stiffening members into the through-hole and seating its opposite end in the receiving pocket, bonding each of the stiffening members to the body with an adhesive material to form a combined wax mold, and casting a golf club head from the combined wax mold.

Abstract: Methods of manufacturing a golf club head with one or more stiffening members proximate the face, and particularly solid rods or a plate with one or more cutouts, is disclosed herein. One method includes the steps of preparing a wax mold of a golf club head including a plate stiffening member with excess material, casting the golf club head, and machining away the excess material. Another method includes the steps of casting a golf club body, providing a plate stiffening member, providing a face component such as a face cup, tack welding the plate stiffening member and the face component to the golf club body, and welding these parts together.

Abstract: Provided is a method of making a cured object having a surface coating bonded thereto, which may include: providing an intermediate object produced in an additive manufacturing process such as stereolithography by light polymerization of a dual cure resin, the resin comprising a mixture of (i) a light polymerizable first component, and (ii) a second component that is different from the first component; applying a first reactive coating composition to a surface portion of the object to form a first coating thereon; optionally, but in some embodiments preferably, applying a second reactive coating composition to the first coating to form a second coating thereon; and heating the object at (and for) a time and to a temperature sufficient to bond the first coating to the surface portion, and bond the second coating when present to the first coating, and form the cured object having a surface coating bonded thereto.

Abstract: A compression wheel for a turbocharger includes: a wheel hub; and a plurality of blades that are arranged around the wheel hub in a spiral shape, where a round portion is provided at a tip of a leading edge of each of the blades.

Abstract: A method of manufacturing a golf club head with a plurality of stiffening members proximate the face, and particularly solid rods or a plate with one or more cutouts, is disclosed herein. The method includes the steps of preparing a wax of a golf club head body having at least one through-hole, a hollow interior, and at least one receiving pocket, preparing waxes of one or more stiffening members, inserting the wax of the stiffening members into the through-hole and seating its opposite end in the receiving pocket, bonding each of the stiffening members to the body with an adhesive material to form a combined wax mold, and casting a golf club head from the combined wax mold.

Abstract: Embodiments of golf club weight attachment mechanisms are described herein. In some embodiments, a golf club head comprises a head body with an interior cavity, a shell portion, and a bracket with a weight member coupled to the bracket. In one embodiment, the bracket and the weight member can be configured to be fully contained within the interior cavity. Other examples and related methods are also described herein.

Abstract: The present invention provides a shaped component for a compressor wheel that can be used to manufacture a turbo compressor wheel which is excellent in terms of high-temperature strength, rigidity, and dynamic balance and, furthermore, has optimal performance suitable for diverse required characteristics in individual portions.

Abstract: A composite core die includes a reusable core die; and a disposable core die. The disposable core die is in physical communication with the reusable core die and surfaces of communication between the disposable core die and the reusable core die serve as barriers to prevent the leakage of a slurry that is disposed in the composite core die.

Abstract: A method for manufacturing a high-strength steel wooden golf head solves the difficulty in reducing the thickness of the striking faceplate of a conventional wooden golf head. The method includes placing a shell mold having a crucible portion and a cavity portion in communication with the crucible portion on a rotary table, placing a metal ingot in the crucible portion, followed by melting the metal ingot into molten metal in a vacuum environment, rotating the rotary table to cause molten metal to flow into the cavity portion under a centrifugal force, gradually slowing down the rotary table after the molten metal cools and solidifies, destroying the shell mold to obtain a casting including a cast product portion, and separating the cast product portion from the casting to obtain a casting product of the wooden golf head having a tensile strength of 240-350 ksi and a minimum thickness of 1.4-1.8 mm not including a groove depth of the striking faceplate.

Abstract: A method includes placing a shell mold with a crucible portion and a casting portion in communication with the crucible portion on a rotary table, with the heterogeneous material including an embedded portion inlaying in the casting portion of the shell mold and a non-embedded portion locating in a cavity of the casting portion, placing a metal ingot into the crucible portion, followed by melting the metal ingot into molten metal in a vacuum environment, rotating the rotary table, causing the molten metal to flow into the cavity, destroying the shell mold after the molten metal solidifies to obtain a casting including a cast product portion separated from the casting to obtain a cast product of a golf club head, and removing the embedded portion of the heterogeneous material protruding from an outer periphery of the cast product of the golf club head.

Abstract: A method for manufacturing a low-density steel wooden golf head solves the difficulty in reducing the thickness of a conventional wooden golf head. The method includes placing a shell mold having a crucible portion and a cavity portion in communication with the crucible portion on a rotary table, placing a metal ingot into the crucible portion, followed by melting the metal ingot in molten metal in a vacuum environment, rotating the rotary table to cause the molten metal to flow into the cavity portion under a centrifugal force, gradually slowing down the rotary table after the molten metal cools and solidifies, destroying the shell mold to obtain a casting including a cast product portion, and separating the cast product portion from the casting to obtain a casting product of a wooden golf head having a density of 6.5-7.6 g/cm3 and a minimum thickness of 0.4-0.6 mm.

Abstract: A prefabricated sprue assembly provides attachment to independently-produced investment casting molds to substantially reduce the need for pattern material. Installable connections between the prefabricated sprue assembly and the investment mold allow substantial reduction of scrap loss caused by errors in production of individual investment molds by culling defective molds before installation to the sprue assembly.

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.

Abstract: The invention relates to a method for manufacturing the impeller of a centrifugal, that is, a radial compressor or radial blower, said impeller being mounted directly on the shaft of an electric motor. An essential feature of the invention is that the composite material impeller is made using an RTM process, wherein the RTM mold has a core and accurately trimmed fabrics placed therein in such a manner that the fabric layers, or preforms, are pulled onto the core thus achieving a maximally optimized use of materials in the structure.

Abstract: A turbocharger including a turbine wheel having a hub-to-tip ratio of no more than 60% and blades with a high turning angle and a curved leading edge, a turbine housing forming an inwardly spiraling primary-scroll passageway that significantly converges to produce highly accelerated airflow into the turbine at high circumferential angles, and a two-sided parallel compressor. The compressor and turbine each produce substantially no axial force, allowing the use of minimal axial thrust bearings.

Abstract: There is provided an imprint material forming a film having high abrasion resistance even after a pattern has been transferred thereto, specifically an imprint material forming a film having a small number of pieces of scratch when the film after a pattern has been transferred thereto is subjected to a steel wool abrasion test. An imprint material comprising: a component (A): a compound having at least one ethylene oxide unit and having at least one polymerizable group; a component (B): a polycaprolactone-modified urethane compound having a C13-25 long chain alkyl group and at least one polymerizable group; and a component (C): a photopolymerization initiator.

Abstract: A method for manufacturing a high-strength golf iron head with a thin striking faceplate includes placing a shell mold onto a rotary table. At least one metal ingot is placed into a crucible portion of the shell mold and melts in a vacuum environment. The rotary table rotates to cause the molten metal to flow into a cavity portion of the shell mold. The rotating shaft is slowly stopped, and the shell mold is removed after pouring. The shell mold is destroyed after the molten metal cools and solidifies, obtaining a casting. A cast product portion is separated from the casting to obtain at least one golf iron head subsequently treated with heat treatment to provide a striking faceplate of the golf iron head with a tensile strength of 280-340 ksi, an elongation of 4%-20%, and a minimum thickness of 1.4-1.8 mm excluding a groove depth of the striking faceplate.

Abstract: A method for manufacturing a high-strength blade-type golf iron head with a thin blade includes placing a shell mold onto a rotary table. At least one metal ingot is placed into a crucible portion of the shell mold and is heated to melt in a vacuum environment. The rotary table rotates to cause the molten metal to flow into a cavity portion of the shell mold. The rotating shaft is slowly stopped, and the shell mold is removed after pouring. The shell mold is destroyed after the molten metal cools and solidifies, obtaining a casting. A cast product portion is separated from the casting to obtain at least one blade-type golf iron head having the blade with a minimum thickness of 3.5-5.0 mm. The weight of the blade-type golf iron head is reduced by 0.9-2.5%, and the center of gravity of the blade-type golf iron head is lowered by 0.2-0.75 mm.

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: Integral liquid-coolant passageways in an x-ray tube. In one example embodiment, an x-ray tube includes a can at least partially defining an evacuated enclosure, a cathode at least partially positioned within the evacuated enclosure, and an anode at least partially positioned within the evacuated enclosure. The can has first integral liquid-coolant passageways formed therein. The can is configured to have a liquid coolant circulated through the first integral liquid-coolant passageways to thereby cool the can without the can being submersed in a liquid coolant.

Abstract: The process for investment casting of complex shapes has historically had 6 basic steps in it. Depending upon the path taken, these discrete steps have been reduced to either 5 steps, or to 2 steps, discarding the unwanted steps. Instead of having to generate the shape of each sacrificial pattern, the process generates either (A) a male tree containing a plurality of sacrificial patterns, already on their runners, onto which a mold shell can be formed, or, (B) a female shell, made of a refractory material, and forming internally the outside surfaces of the plurality of patterns and runners. This process removes both capital expenditure for tooling and process time by up to 90%. By removing several lengthy, time-dependant steps from the process the part cost and lead time are reduced.

Abstract: An intermediate case (IMC) for use in a compressor section of a gas turbine engine includes a bleed duct and an IMC centerbody. The bleed duct is formed via sand casting. The IMC centerbody is formed via investment casting and is fixedly attached to the bleed duct.

Abstract: A method for digital manufacturing of a jewelry item includes printing a three-dimensional wax model on a substrate and printing a three-dimensional sprue, the sprue being adapted to support the wax model. A fixture for handling wax models includes a platform, a plurality of holders, a plurality of standoffs, and a tie. A method of manufacturing a jewelry item, comprises forming a first wax model for a portion of a jewelry item, forming a second wax model for a portion of a jewelry item using a rapid prototyping process, and performing one or more lost wax processes with the first and second portion to create the jewelry item.

Abstract: A casting method for obtaining a part that includes a tapering portion, and also a turbine engine blade obtained by casting and including a tapering trailing edge. According to the invention, the method comprises the following steps: providing an insert element having a tapering portion; making a shell around the insert element; and casting a molten material into said shell including the insert element.

Abstract: A method of providing a positive three-dimensional image of a textured object on metal jewelry, plates, or tags, etc. The textured object may be a finger, fingertip, or any object with a three-dimensional texture. A negative-impression mold is formed in a thermoplastic material, and a positive-impression model then obtained from the negative-impression mold. The positive-impression model is used in the lost-wax process to obtain a piece of metal jewelry having the positive, three-dimensional image of the textured object. The jewelry may be a ring, a pendant, a bracelet, etc., made of gold, silver, platinum, or other metal.

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

Abstract: A method involves forming a core assembly. The forming includes deforming a wire, the deforming including increasing a transverse linear dimension along at least one portion of the wire. The wire is assembled to a ceramic core.

Abstract: A casting core assembly includes a metallic core and a ceramic core. The process for forming the casting core assembly includes inserting a ceramic plug of a metallic core and ceramic plug core subassembly into a compartment of the ceramic core. The ceramic plug is secured to the ceramic core.

Abstract: A method of forming a cast component includes at least partially surrounding an investment mold in a heat-insulating packing material, feeding a molten alloy into the investment mold to provide a filled investment mold, and agitating the filled investment mold while solidifying the molten alloy.

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 sprue for use in investment casting may comprise a pin and a shell enclosing a part of the pin. A method for creating a sprue may comprise partially enclosing a pin in a shell.

Abstract: The pattern has a pattern material and a casting core combination. The pattern material has an airfoil. The casting core combination is at least partially embedded in the pattern material. The casting core combination comprises a metallic casting core and at least one additional casting core. The metallic casting core has opposite first and second faces. The metallic core and at least one additional casting core extend spanwise into the airfoil of the pattern material. In at least a portion of the pattern material outside the airfoil of the pattern material, the metallic casting core is bent transverse to the spanwise direction so as to at least partially surround an adjacent portion of the at least one additional casting core.

Abstract: Removing of a casting core from a metal casting leaves at least one opening in a surface of the metal. The opening is filled with a sacrificial material. The metal and sacrificial material are machined at the opening. After the machining, a remainder of the sacrificial material is removed.

Abstract: In precision casting of metallic components with very thin passage ducts, in particular turbine blades, by the lost-wax process, the ceramic core pins provided for forming the passage ducts are covered and stabilized via a low-melting reinforcing coat prior to injection of the wax material required for forming the wax pattern for the production of the ceramic casting mold, with the low-melting reinforcing coat being melted out together with the wax material after the casting mold has been formed on. The ceramic core pins are therefore not damaged during the production of the wax pattern, enabling very thin passage ducts to be formed in the precision casting process.

Abstract: A method of forming a hollow sand core involves placing a preform into a cavity defined in a mold, where the preform has a predetermined configuration. A granular material is then introduced into the mold cavity and around the preform. The introduced granular material is established around the preform to form the hollow sand core. The preform is deformed in a manner sufficient to enable removal of the preform from inside the hollow sand core, and then is removed from the sand core. The removal of the preform exposes a hollow portion of the sand core.

Abstract: A process for creating a lost wax tree, including the steps of assembling a wax tree having a wax pattern and a wax runner, using automated equipment to flex either the wax tree or the wax pattern to bring disconnected sections into proximity, heating at least one of the disconnected sections, contacting the disconnected sections and then moving the sections slightly away from one another. A process for casting a part including the steps of creating a lost wax tree and where the wax tree is later covered with a mold material and the wax tree is removed to create a mold, the mold is then used to cast a part similar to the wax pattern. A lost wax tree having a wax tree with a wax pattern and a wax runner, automated equipment for flexing, a heating element, and automated equipment for manipulating disconnected sections.

Abstract: System and methods involving pattern molds are provided. In this regard, a representative system includes a mold assembly unit having a movable fixture holder operative to engage a portion of a pattern mold and position the pattern mold for assembly.

Abstract: Method for producing a mold for use in casting reactive metals comprising preparing a slurry of a yttria-based refractory composition and a binder, and using said slurry as a mold facecoat by applying said slurry onto a surface of a mold pattern, wherein said yttria-based refractory composition is obtainable by (a) mixing particles of a yttria-based ceramic material and a fluorine containing dopant, and (b) heating the resulting mixture to effect fluorine-doping of said yttria-based ceramic material.

Abstract: A method of making a wax mold for a golf club head includes the steps of: a) positioning a male die in a cavity of a female die; b) injecting and filling dissolvable wax into a gap between an outer surface of the male die and an inner surface of the female die; c) cooling and solidifying the dissolvable wax in the gap to obtain a wax shell; d) removing the wax shell from the male die and the female die, the wax shell being provided with a hole extending through inner and outer surfaces of the wax shell; and e) inserting a wax plug into the hole to form the wax mold.

Abstract: A system and method of drying casting molds for forming metal parts is provided. In one embodiment, the method includes providing a casting mold comprised of a meltable pattern coated with a ceramic slurry containing a liquid solvent and a binder, placing the casting mold in a chamber, encapsulating the casting mold in a desiccant material, sealing the chamber sufficient to pull a vacuum in the chamber, and applying a variable vacuum to the chamber to dry the mold. In one embodiment, the vacuum is controlled and gradually increased over time from atmospheric pressure to a predetermined maximum vacuum pressure. The vacuum is preferably applied at a rate such that the meltable pattern has a temperature that does not decrease more than about 5 degrees F. from atmospheric pressure to maximum vacuum pressure in one embodiment. In another embodiment, the retained moisture level of the desiccant may be controlled to minimize temperature swings of the meltable pattern during the vacuum application.

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 sprue former of the type used to produce a casting mold includes a generally hollow body or a body having hollow sections. The body includes an inlet forming member and at least one first interface member. The inlet forming member is configured to provide an inlet cavity in the casting mold to enable casting material to enter the casting mold. The first interface members are configured to couple to casting patterns. The casting patterns represent items to be cast. The body can also includes a reservoir forming member and at least one connecting member coupling the reservoir forming member to the inlet forming member.

Abstract: The present invention is a novel sprue rod assembly for lost wax investment casting and its method of use. The sprue rod is reusable because it is made of material with a high melting point, such as metal, instead of wax. The sprue rod assembly also comprises a weight pull system, which causes the sprue rod to fall out of the investment mold when it is heated prior to dewaxing or early during dewaxing. The reusable sprue rod assembly reduces wasted wax, increases the efficiency of dewaxing and decreases flaws from the expansion of trapped wax during dewaxing. In addition, the sprue rods can be stacked to create the desired length.

Abstract: A method of forming a pattern includes providing an actual core having dimensions which are different from dimensions of an ideal core. A best fit spatial relationship of the actual core to a spatial envelope for an ideal core is determined. Locating surfaces in a die are moved to positions, at least some of which are offset from ideal core locating positions, in which the actual core is positioned in a best fit spatial relationship with the spatial envelope for the ideal core. A plurality of motors may be utilized to move the core locating surfaces to desired locating positions. The actual core is positioned in engagement with the core locating surfaces and a flow of wax is conducted into the die. If desired, a best fit spatial relationship of the actual core to a die cavity may be determined, rather than a best fit with an ideal core.

Abstract: In an investment casting procedure using microwave energy as the heat source virgin wax models are attached to a spree of wax-type pattern material incorporating a susceptor, the spree having a pour cup also of a wax-type pattern material, the pour cup material having a higher percentage of the susceptor than the material of the spree. In use the pour cup will melt first and the spree second, unblocking the path of the virgin wax so that its expansion will not crack ceramic with which it has been coated.

Abstract: A method of forming a gating fixture for a lost wax casting process includes determining an optimal orientation of a gate in relation to a part, and forming a fixture that can repeatably be used to consistently locate the gate relative to the part. In one example, stereolithography is used to form the fixture.

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.