Abstract: A process is disclosed for the preparation of ceramic cores which includes injection by means of a press of low power of liquid wax into cavities of a ceramic core disposed in a mould of elastomer produced by moulding of a dummy core which is a replica of the core to be produced.

Abstract: Both a pattern member and a body of expansion material are covered with a layer of ceramic mold material. The body of expansion material has a coefficient of thermal expansion which is greater than the coefficient of thermal expansion of the ceramic mold material. The layer of ceramic mold material and the body of expansion material are heated. This results in a cracking of the layer of ceramic mold material by the body of expansion material due to greater thermal expansion of the body of expansion material as it is heated. During the step of heating the ceramic mold material and body of expansion material, the pattern member is melted to separate the pattern from the layer of ceramic mold material.

Abstract: To form a turbine engine component, metal airfoils are positioned in an annular array. Outer end portions of the airfoils are embedded in a wax outer shroud ring pattern and inner end portions of the airfoils are embedded in a wax inner shroud ring pattern. A mold is formed by covering the metal airfoils and the shroud ring patterns with ceramic mold material. The wax of the shroud ring patterns is then removed from the mold to leave inner and outer shroud ring mold ring cavities. The shroud ring mold cavities are filled with molten metal which is solidified to form inner and outer shroud rings interconnecting the airfoils. To accommodate thermal expansion of the airfoils relative to the shroud rings, a slip joint is provided between at least one end portion of each of the airfoils and a shroud ring. To enable the slip joint to be formed, molten metal solidifies in the shroud ring to be formed, molten metal solidifies in the shroud ring cavities free of metallurgical bonds to the airfoils.

Abstract: A process for producing a hollow metal cast product having a desired interior contour is provided. The process comprises the steps of preparing a first lost model having an outer contour substantially corresponding to a desired interior contour of the finished product, depositing a metallic or ceramic material or a mixture thereof over the surface of said first lost model by spraying to form a layer defining a hollow core block, placing said hollow core block in a first mold, pouring or injecting a material for forming a second lost mold into said first mold to form a second lost model, coating a refractory material over said second lost model to form a second mold for casting, removing second lost mold to form a cavity, casting a molten metal or alloy into said cavity, and staving said second mold to take out a finished product.

Abstract: The present invention relates to a mold material for casting pure titanium or a titanium alloy which comprises one or more chief materials selected from among silica-alumina mixtures, mullite and spinel and a hardening agent comprising a phosphate and a basic metal oxide and a process for casting pure titanium or a titanium alloy by the use of said mold material. This mold material forms a refractory structure having a melting point higher than that of pure titanium or a titanium alloy therein to enable pure titanium which is unstable in a molten state to be cast stably.

Abstract: A wax ring tube used in manufacture of a ring-like ornament by casting it using a lost-wax process. Plotting graduations are formed on inner peripheral wall surface of a hole bored along the lengthwise direction of a wax ring tube body.

Abstract: An investment casting process employs a low-cost plastic pattern manufactured by machining. A mold is cast around the plastic pattern following which the pattern is removed from the mold to leave a mold cavity which molten metal or the like may be poured to produce a finished part. Reusable plastic patterns may be formed by casing silastic rubber. The silastic rubber patterns may be mechanically separated from the mold without damaging the pattern.

Abstract: Gate is a wax structure for forming part of a wax master in investment casting of a dental prosthesis. The gate has a square feeder with a circular disc on each end. The square feeder reduces the cracking stresses between adjacent feeders to reduce unwanted fins, and the square shape aids in final cutoff of the cast prosthetic. In the wax master, one of the discs is secured to the prosthetic form and the other disc to the conventional reservoir bar. The disc shape aids in filleting to the form and bar.

Abstract: A foundry process and associated apparatus for providing mixing of water, an additive, and a casting (investment) for the automated powder, which once mixed, are to be delivered to molds to form casting molds such as in the fabrication of microwave components (castings). The apparatus comprises a source of water, a source of additive and a source of the casting powder. There is provided a mixing bowl and automatic control means for coupling the water and additive to the mixing bowl and thereafter delivering the investment powder to the mixing bowl to provide for the thorough mixing of all of these components. The mixing bowl has associated therewith a manually operated valve which permits delivery of the mixed material into flasks disposed in a mixing chamber disposed under the mixing bowl. In accordance with the control provided in accordance with the invention, the mixing occurs initially without vacuum over a first predetermined period of time which may be on the order of 1-3 minutes.

Abstract: A molding medium and process for making it, preferably for use in the evaporative pattern casting process, is disclosed. The molding medium comprises, in one embodiment, a base granular molding material having spherically shaped grains wherein the individual grains of the material are coated with a refractory material. Preferably the grains are coated first with a binding agent and then mixed with a refractory material, which may be zirconium oxide. After coating, the material is fired at a high temperature, crushed and screened to size, according to one method. Alternatively, the base molding material may itself be a refractory material, in which case the refractory material is mixed with a binding agent to agglomerate the base material into substantially spherical particles and a refractory coating need not be applied. In either embodiment, substantially spherical free-flowing particles are produced having a low angle of repose.

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: A method of making jewelry or the like to enhance the retention of a gem to a retaining bezel area of the jewelry, comprising the steps of obtaining and utilizing the gem as a model initially, casting the gem in a moldable material, allowing the moldable material to set, dividing the set moldable material into segments to expose the gem, thereby providing a recess in at least two divided moldable material segments thus formed, removing the gem to expose the recesses, casting into the recesses a material which is soluble in the presence of a fluid so that the cast material has an external configuration of the gem when set, allowing the cast material to set, removing the cast material from the recesses of the moldable material, crafting a temperature sensitive substance about the cast material to form the bezel area and attendant jewelry, removing the set soluble material in the presence of the fluid, vaporizing the temperature sensitive substance with molten material using a lost wax process, allowing the molt

Abstract: A hollow metallic head having a ball striking front face and a bottom surface,(b) the head defining an opening between the hollow and the exterior, the opening located at the bottom of the head, the head having a heel and toe,(c) and a closure for that opening having elongated, tongue and groove, linear sliding connection with the head, the closure located at the bottom of the head, the closure directly exposed along its length to the head hollow above the closure,(d) the connection having a substantially T-shaped cross section, the closure being longitudinally elongated in the direction between the hell and toe, and the connection comprising two pairs of tongue and groove elements, each pair including a tongue element on the closure and a groove element on said head to limit inward displacement of the tongue elements, the closure having a lowermost outer surface everywhere spaced from the tongue and groove elements and flush with the head bottom surface at opposite sides of the closure lowermost outer surfac

Abstract: The present invention provides a method for manufacturing a thin-walled ceramic casting mould which is particularly suitable for casting directionally solidified articles in which rapid cooling of the cast material is required. The mould is transfer moulded around a disposable pattern material and includes an integral core. The mould has an outer wall thickness of the order of 0.5 mm to 2.0 mm. The mould and core may be made of the same or different ceramic materials chosen for their strength or thermal conductivity. The method further provides for a series of high temperature disposable supports embedded in the disposable pattern material, providing support for the outer wall of the mould during the firing process. The disposable supports are disposed of at a temperature at which the mould has acquired self-supporting strength.

Abstract: As a substitute for brazing conventionally employed for attaching curved pad holders to rims of an eyeglass-frame, casting is used for formation of an eyeglass-frame including, in one body with its rims, straight pad holders which should thereafter be bend to a required configuration. Conventional troubles arising from use of brazing are fully removed.

Abstract: A method of making individual castings. In the production of individual castings, in particular in dental engineering, the casting is usually premodeled in wax. However, this casting model is very susceptible to deformation, which leads to inaccuracies in the fit of the casting. With the present method, at least a part of the casting model is built up from a photopolymerizable compound which burns leaving no residue. Advantageously, the curing is carried out, in the presence of a suitable initiator, with visible light; the basis of the compound is a photopolymerizable (meth)acrylic acid ester. In dental engineering, with the present method there is made possible in a simple manner to build up form-stable casting models for making crowns, bridges, and inlays and, particularly favorably, complicated secondary parts for removable dental appliances.

Abstract: The apparatus comprises an expandable investment ring having a removable base. Formed on the top surface of the base, and within the void defined by the ring, is an indexed sprue former. A curved runner bar having an indexed coping is formed at one end thereof in mating relation to the sprue former. The curved full arch runner bar comprises a proximal end portion and distal end portion with the distal end forming a first and second curved configuration portion which together approximates the curved configuration of the jawbone of a patient. The first and second curved configuration portions are interconnected thereby resulting in extremely accurate full arch base metal castings. The apparatus is also useful for preparing precious metal castings.

Abstract: This invention relates to a process for the production of an implant of metal or plastics material having an open-celled structure as a bone substitute. The process uses a connectively open-celled pattern material having a spatial grid or lattice network structure, the cells or pores of the material being defined or formed by very fine thin interconnected threads or cords. The thin threads are coated by a wax-water emulsion which is combustible and vaporizable. A stabilization of the coating may be performed by spraying-on of a hardening and vaporizable synthetic material lacquer, which is deposited on the wax coating. A core material is introduced into the residual hollow spaces of the pattern, which is consolidated by heat, the pattern material being burnt and vaporized while doing so, together with the adhering material and the lacquer without leaving behind any residues, so that the cavities formed in the core may be filled with the implant material and the core material is finally removed.

Abstract: A mold construction and method for use in producing articles having a predetermined crystalline orientation including single crystals. The technique employs a seed holder or cradle that is inserted into a bottom aperture of a ceramic mold to permit the precise orientation of one or more seeds relative to the article cavity and to provide improved solidification process control. The technique also facilitates pattern assembly and pattern removal operations during fabrication of the ceramic mold.

Abstract: The method for transporting wax structure between first and second positions, and including (a) a support relatively movable into adjacency to said structure, (b) prong means associated with said support and movable relative thereto between retracted and advanced positions, the steps that include (i) advancing said prong means in non-parallel direction into said advanced position penetrating said wax structure, and (ii) displacing said support and prong means to transport said wax structure.

Abstract: In an investment casting method, a wax coating is provided to the exterior and interior surfaces of a thin-walled hollow metallic form. The wax coating on the exterior and interior surfaces is coated with a mold forming material. When the metallic form is heated, the wax will melt permitting removal of the form.

Abstract: A method of manufacturing a mould for use in the investment casting of a hollow gas turbine engine blade in which a ceramic core is coated with a surface modifying material prior to the application of wax thereto to define a pattern of the object to be cast. The surface modifying material adheres to the core and provides a textured surface to which the wax keys, thereby preventing the wax lifting from the core.

Abstract: A spruing assembly for receiving investment material in the production of an investment mold for castings by the "lost wax" process which includes a hollow chamber to receive the investment material formed by a base member and an engaging tapered ring. A horizontal feeder bar is contained within the chamber and is supported by hollow sprue means. The feeder bar is open at its top and has a narrow channel for conducting molten wax into the hollow sprue support. The base member includes a centralized sprue base former and support means associated with the former to provide support for the hollow sprue means supporting the feeder bar.

Abstract: A method for the manufacture of an investment shell mold is disclosed which comprises applying to the surface of a wax pattern at least one layer of slurry formed by dissolving in an organic solvent a soluble organic cellulose derivative containing a dispersed metallic oxide, subsequenty applying to the first layer at least one layer of slurry formed by mixing a refractory powder with a cellulose binder, and thereafter causing the applied slurry layers to set and removing the pattern by the ordinary method.

Abstract: A method of manufacturing durable metal molds whereby metal melt-spraying is utilized. The method comprises the steps of spraying a first model with a low melting point metal, removing the first model, casting a second low melting point metal into the space vacated by removal of the first model to form a second model, removing the second model, spraying the second model with a high melting point metal, melting said second model out of the mold formed by spraying the high melting point metal, reinforcing the space vacated by the melting of the second model with sand, and reinforcing the space to the rear of the mold with metal, cement, or any suitable material. The sand is subsequently removed to form a durable metal mold.

Abstract: A vertical pressure die casting apparatus comprising a stationary member, an air-permeable die detachably mounted on the stationary member and formed with a cavity including a downwardly open runner portion and a casting cavity portion communicating with the runner portion, a die clamping member to clamp the die vertically between the stationary member and the die clamping member, a sleeve held in position with respect to the stationary member and having a bore upwardly communicating with the runner portion of the cavity in the die, and a power cylinder provided below the die and having a cylinder body fixedly held in position with respect to the stationary member and a piston rod extending upwardly into the sleeve and vertically slidable in the sleeve.

Abstract: A metal charm has the impression of the biting edges of teeth formed in it. It may also be formed in a rubber stamp.

Abstract: The apparatus comprises an expandable investment ring having a removable base. Formed on the top surface of the base, and within the void defined by the ring, is an indexed sprue former. A curved runner bar having an indexed coping is formed at one end thereof in mating relation to the sprue former. By virtue of this apparatus extremely accurate base metal castings may be obtained. The apparatus is also useful for preparing precious metal castings.

Abstract: A casting process for making and utilizing an elastomeric pattern that is coated with a non-metallic material to form a non-metallic shell mold and thereafter removed from the non-metallic shell mold by thermal decomposition or mechanical stripping.

Abstract: A pad eliminatable by heat prior to casting has a patterned surface and a non-porous backing. The pad is sized and shaped into at least part of the appliance and the patterned surface is conformed to the desired bonding surface contour. The patterned surface yields irregularities in the cast bonding surface which increases bondability.

Abstract: The method of fabricating a metal shell golf club head includes forming a core to the form of the inside surface of the shell; forming a plug integral with the core to project outwardly therefrom, the plug formed to outline peripheral shape conforming to the inner peripheral edge of a sole plate opening in the head shell; forming at least one gripper finger opening and at least one locking recess in the side of the plug, the core characterized as being soluble in a fluid solvent; forming a wax shell about the core while locating the plug in fixed position in a mold to hold the core in predetermined position and while maintaining a locking plunger in the formed recess; and removing the core and plug relative to the wax shell by dissolving the core and plug in the solvent; the core being transferred between stations (at which the (a) and (b) steps are carried out) by gripping and bodily displacing the plug which is integral with the core.

Abstract: A method of making at least the aerofoil of a blade for a gas turbine engine in which the cooling air exit passages, whether at the trailing edge or in other parts of the aerofoil, are cast rather than machined subsequently. In the method a disposable piece is formed with holes of the shape of the holes eventually required in the blade aerofoil. The piece is placed in a die and used to define part of the ceramic core required in the casting process, the die being arranged to produce a channel portion interconnecting the otherwise free ends of the parts of the core which will form the passages. The ceramic core thus formed in a lost-wax casting process to form the blade aerofoil, the channel portion being embedded in the shell mould to support the parts which define the passages.

Abstract: A blade or vane structure for a gas turbine engine comprises a hollow aerofoil member and a cooling air entry tube within the hollow aerofoil member, the aerofoil and the tube comprising a unitary cast structure. To make this structure it is proposed that a lost wax casting process should be utilized, with the internal cavities formed using ceramic cores formed with the aid of temporary, disposable pieces which define the space eventually occupied by the tube.

Abstract: A method of making a two part aerofoil gas turbine engine blade consisting of casting each individual part separately, the parts being cast by the lost wax process, and subsequently joining the parts together after machining.

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: Articles of jewelry with gems set in precious metal are cast by a modified lost wax method whereby each gem is retained in position in the investment mold after removal of the wax enabling the setting of the gem to be simultaneous with the casting of the precious metal. The wax model of the article of jewelry is molded with undercut grooves in the sidewall of the gem seat located to engage portions of the girdle of the gem for retention thereof in set position in the finished article. The wax for the model is formulated to provide resiliency to permit the gem to be snapped into position in the wax model prior to embedding the model with the gem set therein in investment material in the conventional flask. Curing time is reduced to approximately one half the conventional fourteen hours by precise control of predetermined time and temperature which also prevents marring of the gems during the curing of the investment and the casting of the precious metal.

Abstract: A method of casting a blade or vane for a gas turbine engine which enables the production of more complex internal shapes than those which may be made by prior art methods. The method of the invention includes the steps of:making a temporary filler piece from a disposable material,holding the filler piece in place in a die,injecting the core material into the die and causing it to solidify round the filler piece,removing the core from the die,causing the filler to be removed from the core to leave within the core a cavity having the shape of the filler, andusing the core thus produced in an investment casting process to form the blade or vane shape.

Abstract: A finished ceramic airfoil is provided having within it a lining of thermal insulation and a fusible core having the desired contour of the metal core of the turbine blade. A casting mold is provided around the airfoil. The fusible core is melted and removed, leaving a cavity in the airfoil surrounded by the insulation lining. The cavity is filled with molten metal which is allowed to solidify to form the metal core of the turbine blade.

Abstract: A wax pattern and runner assembly includes resilient means whereby upon expansion of the wax upon removal from a ceramic mould the resilient means are compressed.

Abstract: A method of making a form of a desired shape, for use in an investment casting technique which comprises forming a first sheet of formable material to a shape which approximates to the desired shape of the form, disposing the formed shape around a layer of deformable hardenable material, applying a compressive force to the formed shape to deform the underlying hardenable material to a desired shape, hardening the hardenable material to produce a form precursor, removing the formed shape from the hardened form precursor and utilizing the hardened form precursor to form a second sheet of formable material into the form of the desired shape. The invention also includes a method of making crowns by an investment casting technique utilizing the form produced by this method.

Abstract: Disclosed is a prefabricated pontic framework formed of a non-precious material and method to be used in making dental bridges. The prefabricated pontic framework comprises a plurality of pontic supports with a connecting bar mounted on opposed sides of each pontic support, such pontic framework being selected and cut to size for a particular bridgework situation.

Abstract: Method and apparatus for producing ceramic shell molds characterized in that a plurality of pattern set-ups are arranged with their longitudinal axes transverse to an axis of rotation and are rotated as a group while applying fluent refractory material to produce either a multiple number of molds or a single mold. A ceramic shell mold characterized by a main sprue passage, a plurality of transverse sprue passages extending therefrom, and casting cavities gated into the transverse passages.

Abstract: An integral stainless steel golf club head having a lead insert positioned directly behind the center of the intended striking surface of the club head is provided by using a "lost wax" procedure to mold an internally screwthreaded recess in the rear surface of the club head, into which a correspondingly threaded lead insert of selected weight and length is inserted.

Abstract: A refractory suspension comprising (parts by weight): coke, 10-60; powdered metallic titanium or/and zirconium, +0.3-5.0; resol resins, 5-50; a hardener, such as an inorganic acid, 2-30; an organic solvent, 20-60.The proposed suspension allows making foundry moulds exhibiting a higher strength. The castings produced in said foundry moulds are superior in accuracy by 2 classes, according to the USSR classification, to those obtained by the prior-art methods.

Abstract: The material used for the production of cores for precision molds is a metal which is oxidizable at relatively low temperatures, i.e., below the solidification temperature of the melts for pouring, and which passes directly from the solid state to the gas state by oxide sublimation. This greatly speeds up the dissolving of cores, particularly small diameter cores, out of the castings.

Abstract: A method of casting metal so that the finished casting will hold a precise dimension in certain critical areas in order to enable the finished casting to be used as a frame for objects such as coins and medallions which are die struck to precise dimensions. Means of and apparatus for rigidly maintaining the object inside the cast frame by inexpensive means which will not damage the object and which will allow the object to be easily removed from the frame if necessary.

Abstract: A method of manufacturing a mold adapted to be used for casting bodies of fiber-reinforced composites. A model of the body to be cast is prepared and coated with a one-piece dense shell of refractory metallic oxide deposited by plasma or flame spraying and the model is then separated from the shell by conventional physical or chemical treatment.

Abstract: A casting tree for preparing a tandem mold suitable for sequential casting, within the same casting flask, of both white and yellow gold portions of jewelry items has a base with a main stem extending upwardly from the base. In addition, a secondary stem is also provided and extends from the base to an upper portion of the main stem. Both stems are formed of a fusible material generally termed as "casting wax." Disposed through the central portion of the main stem, between the base and the upper portion to which the secondary stem extends, is a piece of non-fusible material, preferable a ceramic disc.When the subject invention tree is used in an investment casting process, the casting mold formed thereby comprises a tandem mold divided by a non-fusible separator, each portion of the mold having a separate passage communicating therewith whereby two different types of material, for example, a white gold and yellow gold, can be separately cast using one flask.

Abstract: In a shell investment casting process a reusable pouring cup form is used. The shell mold is built up around both the pattern and the pouring cup form. When the pattern wax is removed, the pouring cup form is also removed to leave a formed in situ pouring cup. A significant feature is that the pouring cup has a rolled lip that is relatively strong and does not tend to cast debris into the mold. This lip facilitates handling of the shell mold.

Abstract: A method of producing cast metal tooling, especially injection molds or dies, characterized by the steps of making a thin walled, investment cast shell which defines the functional cavity surface of the tooling, and casting a suitable backing metal against the shell to form a composite die or mold structure.