Abstract: A slurry composition for a mold and method of use thereof. The slurry composition includes about 45-80% by weight alumina, about 10-30% by weight silicon carbide, and about 10-50% by weight colloidal silica. In one aspect, the alumina component comprises a material selected from the group consisting of brown fused alumina, white fused alumina, tabular alumina, calcined alumina, and mixtures thereof. In another aspect, the composition includes fumed silica at 2-5% by weight. The composition may also include a setting agent at 0.05-2% by weight.

Abstract: A mold having a shell and a porous layer formed on the surface of the cavity of the shell. The mold can be suitably used for manufacturing a porous body having a porous layer on the surface thereof. The method for manufacturing the mold, includes the steps of forming a layer of combustible powdery particles around a wax mold, which is a lost pattern, a step of forming a film of a ceramic precursor slurry around the wax mold having powdery particles formed thereon, a step of subjecting the resultant product to a heat treatment, to thereby dewax the wax mold, and a step of firing the slurry film, to thereby burn and vanish the powdery particles in the slurry film and form a shell.

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.

Abstract: An investment casting core combination includes a metallic casting core and a ceramic feedcore. A first region of the metallic casting core is embedded in the ceramic feedcore. The metallic casting core includes a plurality of body sections. The first region is along at least some of the body sections. The metallic casting core includes a plurality of springs spanning gaps between adjacent body sections and unitarily formed therewith.

Abstract: Methods for rapid prototype casting metal components, wherein the metal components are cast in a secondary ceramic mold, the secondary ceramic mold is cast in a primary mold, and the primary mold is formed by rapid prototyping or rapid manufacturing. The secondary ceramic mold may comprise a one-piece integral shell and core(s), and the metal components may have at least one hollow portion or void therein, such as a hollow airfoil for a gas turbine engine.

Abstract: At least one feedcore and at least one wall cooling core are assembled with a number of elements of a die for forming a cooled turbine engine element investment casting pattern. A sacrificial material is molded in the die. The sacrificial material is removed from the die. The removing includes extracting a first of the die elements from a compartment in a second of the die elements before disengaging the second die element from the sacrificial material. The first element includes a compartment receiving an outlet end portion of a first of the wall cooling cores in the assembly and disengages therefrom in the extraction.

Abstract: A method of manufacturing a chassis is provided.

Abstract: A synthetic model of a component is created from a 3-D numerical model thereof. A core is then cast inside the synthetic model. The synthetic model may then be removed from the cast core, and then the cast core is used for casting an authentic component therearound. The core is removed from inside the authentic component, which authentic component precisely matches the original synthetic model therefor.

Abstract: A process for the production of a shell mould, comprising the sequential steps of: (i) dipping a preformed expendable pattern into a slurry of refractory particles and colloidal liquid binder whereby to form a coating layer on the pattern, (ii) depositing particles of refractory material onto the coating, and (iii) drying, steps (i) to (iii) being repeated as often as required to produce a shell mould having the required number of coating layers, characterised in that during at least one performance of step (ii) the particles of refractory material have been pre-mixed with a gel-forming material whereby to coat at least a portion of the refractory particles with the gel forming material such that after contact with the coating layer moisture is absorbed by the gel-forming material thereby causing gellation of the colloidal binder so reducing the time required for drying in step (iii).

Abstract: A system for producing cast components from molten metal. One form of the present invention includes a system for the precision pouring of molten metal within a casting mold.

Abstract: A system for producing cast components from molten metal. One form of the present invention includes a system for the precision pouring of molten metal within a casting mold.

Abstract: A method for casting a cooled component includes molding a sacrificial pattern. A plurality of holes are formed through the pattern. A shell is formed over the pattern including filling the holes. The pattern is destructively removed from the shell. A metallic material is cast in the shell. The shell is destructively removed.

Abstract: An investment casting pattern is formed by installing a first core to a first element of a molding die to leave a first portion of the first core protruding from the first element. After the installing, the first element is assembled with a feed core and a second element of the molding die so that the first portion contacts the feed core. A material is molded at least partially over the first core and the feed core. The first portion has one or more surface area enhancements.

Abstract: In accordance with the present invention, a casting system is provided which broadly comprises a core and a wax die spaced from said core, a refractory metal core having a first end seated within a slot in the core and a second end contacting the wax die for positioning the core relative to the wax die, and the refractory metal core having at least one of a mechanism for providing spring loading when closed in the wax die and a mechanism for mechanically locking the wax die to the core.

Abstract: A secondary datum scheme is used for identifying the location of the core-produced internal geometry of hollow investment cast metal parts that are made using a free-floating core design for implementing complex internal structural features. A set of datum pads are cast on a removable portion of the core print out to provide the secondary reference system. This secondary reference system precisely establishes the location of the core-produced internal geometry of the part exclusive of any fixed external primary datum structure/system so that, for example, precision machining and gauging may be performed upon such internal features during subsequent fabrication steps.

Abstract: The invention concerns a die for producing a casting, particularly a component for a motor or other engine, from a reactive molten non-ferrous metal charge using a casting mould and a method for manufacturing the die. The die consists of a casting mould which has a front layer area which comes into contact with the reactive non-ferrous molten metal charge and a top layer area mechanically stabilising the front layer area, the front layer area consisting of a minimum of one rare earth oxide and a minimum of one additional metal oxide, the minimum of one additional metal oxide being selected from the group of oxides of the following metals: titanium and nickel.

Abstract: The present invention relates to a heat dissipating apparatus having micro-structure layer and method for fabricating the same. The method provides two highly heat conductive members having structure patterns. A highly heat conductive material is coated on the structured patterns by means of injection molding for forming a micro-structure layer. The two highly heat conductive members are assembled to form a heat dissipating apparatus having micro-structure layer. The heat dissipating apparatus comprises a main body composed of the highly heat conductive members. The main body forms an accommodating cavity, and inner surfaces of the accommodating cavity form the micro-structure layer. A working fluid is filled into the accommodating cavity for transferring heat from a heat absorbing surface to a heat dissipating surface.

Abstract: According to the prior art, through-holes in components are often introduced after the production (casting) of the component. This entails additional outlay in terms of time and equipment. The time required can be considerably shortened if a casting mold is designed in such a way that the through-hole is at least in part formed by corresponding projections being formed on the inner wall and/or the outer wall of the casting mold.

Abstract: A method for investment casting includes the steps of positioning a base plate relative to a die; molding a first material between the die and at least a first surface portion of the base plate; securing one or more patterns to the base plate, the one or more patterns comprising a second material; applying one or more coating layers over at least portions of the one or more patterns and at least a portion of the first material; substantially removing the first material through an interior receptacle of a manifold body and the second material through an exterior receptacle of the manifold body to leave one or more shells formed by the coating layers; removing said base plate; introducing molten metal to the one or more shells through the interior receptacle of the manifold body; permitting the molten metal to solidify; and destructively removing one or more investment casting molds.

Abstract: In accordance with the present invention, a casting system is provided which broadly comprises a core and a wax die spaced from said core, a refractory metal core having a first end seated within a slot in the core and a second end contacting the wax die for positioning the core relative to the wax die, and the refractory metal core having at least one of a mechanism for providing spring loading when closed in the wax die and a mechanism for mechanically locking the wax die to the core.

Abstract: A deflector element is provided, in order to improve temperature interface control with respect to directional solidification of a component casting. This deflector element is formed during the mould making process and is arranged to be positioned with respect to a part of a principal mould formation within which the final cast component is produced. The deflector element ensures a uniform temperature throughout the component cross-section relative to other parts of the component as it is solidified.

Abstract: A ceramic core for use in casting an article such as for example an airfoil, wherein the ceramic core has a pocket located at or near a region of the core that is otherwise associated with occurrence of a localized casting defect in the cast article. A covering is disposed on the core to cover the pocket and provide core outer surface features.

Abstract: The invention relates to a investment casting shell molds and their method of manufacture. The method entails mixing fiber and refractory filler to form a dry blend; mixing the dry blend with a binder sol to form a refractory slurry, and employing the refractory slurry to produce an investment casting shell mold.

Abstract: A pin used in investment casting, or the lost wax process, to support the ceramic core of a mold includes a core formed of a metal which provides suitable strength to maintain the position of the ceramic core during pouring of molten metal into the mold but which is susceptible to oxidation during firing of the mold. The pin core is encased with an outer coating formed of a metal which resists oxidation during firing of the mold and resists chemical interaction during processing of the cast part. An intermediate coating is preferably disposed between the core and outer coating and is likewise formed of a metal which resists oxidation during firing of the mold and resists chemical interaction during processing of the cast part. The invention also includes an investment casting mold using a plurality of these pins and methods of making the pin and the mold.

Abstract: An investment mould process for forming a cast member is described. The process comprises forming a precursor casting (12) from a master mould (10). The master mould (10) has an internal surface (16) defining a space (14) in which the precursor casting (12) can be formed. The surface (16) defines a location indentation (20) to provide a corresponding location projection (3) on the precursor casting (12). A holding member (22) can be inserted into the location projection (3) to hold an internal member (17A, 17B).

Abstract: A method of casting including forming a shell mold around a pattern fabricated from an expendable material and then removing the expendable material from the shell mold. The shell mold is located within a housing such that an inlet port of the shell mold communicates with an opening in the housing. A supporting material is provided and substantially fills an open volume between an external surface of the shell mold and an interior surface of the housing. A molten material is then pressure cast through the inlet port and into the shell mold. The invention includes a mold assembly and a casting system useful in practicing the disclosed method.

Abstract: An investment mould process for forming a cast member is described. The process comprises forming a precursor casting (12) from a master mould (10). The master mould (10) has an internal surface (16) defining a space (14) in which the precursor casting (12) can be formed. The surface (16) defines a location indentation (20) to provide a corresponding location projection (3) on the precursor casting (12). A holding member (22) can be inserted into the location projection (3) to hold an internal member (17A, 17B).

Abstract: An investment mould process for forming a cast member is described. The process comprises forming a precursor casting (12) from a master mould (10). The master mould (10) has an internal surface (16) defining a space (14) in which the precursor casting (12) can be formed. The surface (16) defines a location indentation (20) to provide a corresponding location projection (3) on the precursor casting (12). A holding member (22) can be inserted into the location projection (3) to hold an internal member (17A, 17B).

Abstract: A mold is provided for enabling casting of single crystal metallic articles including a part-defining cavity, a sorter passage positioned vertically beneath and in fluid communication with the part-defining cavity, and a seed cavity positioned vertically beneath and in fluid communication with the sorter passage. The sorter passage includes a shape suitable for encouraging a single crystal structure in solidifying molten metal. Additionally, a portion of the mold between the sorter passage and the part-defining cavity includes a notch for facilitating breakage of a cast article proximate the notch during thermal stress build-up, so as to prevent mold breakage or the inclusion of part defects.

Abstract: Incorporation of rice hull ash into investment casting shell molds improves the permeability, shell build thickness, and/or shell build uniformity of the molds. A method to make the molds entails mixing refractory filler, rice hull ash, and preferably a fiber to form a dry blend; mixing the dry blend with a binder sol to form a refractory slurry, and employing the refractory slurry to produce an investment casting shell mold.

Abstract: The invention relates to investment casting shell molds and their method of manufacture. The method entails mixing fiber such as ceramic refractory fiber and organic fiber with ceramic filler to form a dry blend. The dry blend is mixed with a binder sol such as colloidal silica sol to form slurry. An expendable preform is dipped into the slurry, stuccoed and dried. This step is repeated until a ceramic shell of a desired thickness is formed over the expendable preform. The expendable preform then is removed, and the green ceramic shell is fired. Molten metal then may be poured into the shell to form a metal casting.

Abstract: A casting device includes a wall which is formed in the manner of a sandwich structure from a front layer, a yielding intermediate layer and a supporting outer layer. In this way, the contraction-related internal stresses which occur during cooling are kept at a low level by the resilient properties of the intermediate layer. As such, the formation of cracks in the component to be cast can be avoided.

Abstract: To prevent movement of a ceramic core in a ceramic shell for the investment casting of a turbine blade, the free end of the core has one or more pins embedded therein so that the pins project into both the core and the ceramic shell which is applied over a wax layer. After removal of the wax and firing of the shell, molten metal is cast in the space left by the wax between the core and the shell. After hardening of the metal, the outwardly projecting part of the pins are removed during the machining of the surfaces of the turbine blade blank.

Abstract: A core box assembly for casting a crankshaft. The core box assembly comprises axially aligned cores that define different axial portions of a cavity that receives molten metal to cast the crankshaft. Oil gallery cores are placed in the core box assembly to form as-cast oil galleries in the crankshaft. Heavy metal inserts are held by sand cores disposed in the portions of the cavity that form the counterweights of the crankshaft.

Abstract: A method of making a ceramic shell mold comprises repeatedly coating a fugitive pattern of an article to be cast with a ceramic slurry layer and applying on the ceramic slurry layer a refractory stucco to form a plurality of ceramic slurry layers and stucco layers on the pattern wherein at least one of the stucco layers is formed by applying discontinuous stucco fiber bundles held together in the bundles by a fugitive binder, which is removed during subsequent firing of the shell mold at elevated temperature.

Abstract: The invention relates to a investment casting molds and their method of manufacture. The method entails mixing refractory fiber, glass fiber, and refractory filler to form a dry blend; mixing the dry blend with an aqueous colloidal silica sol to form a refractory prime coat slurry, and employing the refractory slurry to produce an investment casting mold.

Abstract: A deflector element 3,13 is provided, in order to improve temperature interface control with respect to directional solidification of a component casting. This deflector element 3,13 is formed during the mould making process and is arranged to be positioned with respect to a part 6 of a principal mould formation 2,12 within which the final cast component is produced. The deflector element 3,13 ensures a uniform temperature throughout the component cross-section relative to other parts of the component as it is solidified.

Abstract: Methods for making various titanium base alloys and titanium aluminides into engineering components such as rings, tubes and pipes by melting of the alloys in a vacuum or under a low partial pressure of inert gas and subsequent centrifugal casting of the melt in the graphite molds rotating along its own axis under vacuum or low partial pressure of inert gas are provided, the molds having been fabricated by machining high density, high strength ultrafine grained isotropic graphite, wherein the graphite has been made by isostatic pressing or vibrational molding, the said molds either revolving around its own horizontal or vertical axis or centrifuging around a vertical axis of rotation.

Abstract: A method of casting including forming a shell mold around a pattern fabricated from an expendable material and then removing the expendable material from the shell mold. The shell mold is located within a housing such that an inlet port of the shell mold communicates with an opening in the housing. A supporting material is provided and substantially fills an open volume between an external surface of the shell mold and an interior surface of the housing. A molten material is then pressure cast through the inlet port and into the shell mold. The invention includes a mold assembly and a casting system useful in practicing the disclosed method.

Abstract: A method of forming a ceramic investment shell mold about a fugitive wax pattern of an article comprises coating the pattern with ceramic slurry, applying a ceramic particulate material heated above ambient temperature to the slurry layer, drying the ceramic slurry layer with ceramic particulates thereon, and repeating said coating, applying and drying steps to build up a shell mold on the pattern. The ceramic slurry with ceramic particulates thereon is dried initially dried for a time using relatively low humidity flowing air at an air temperature above about 80 degrees F. and then subsequently for a time using relatively low humidity flowing air at an air temperature not exceeding about 80 degrees F. Ceramic investment shell molds can be built-up in times typically less than 10 hours by practice of the invention with substantially reduced incidence of shell mold cracking during the shell mold building process and subsequent pattern removal operation.

Abstract: In a method of producing a turbine blade in hollow section, an especially low defect or scrap rate is to be ensured. To this end, a first core element is connected via a number of approximately cylindrical spacers to a further core element and/or to a casting mold, the cavities left in the casting mold by the core elements being filled by blade material, and the openings remaining in the turbine blade after the removal of the core elements and the spacers and produced by the spacers being closed by stopper elements.

Abstract: A core for a shell die used in casting a turbine bucket includes an elongated body shaped to create internal cooling passages in the bucket, the elongated body formed with at least one core support pin extending transversely of the elongated body and adapted to fix the core inside the shell die, at least one core support pin having an elliptical shape in cross-section. The invention also relates to a cast turbine bucket with at least one exit hole formed therein during casting. The exit hole and a plug for closing the hole are elliptical in cross-section.

Abstract: A method of making a ceramic shell mold comprises repeatedly coating a fugitive pattern of an article to be cast with a ceramic slurry layer and applying on the ceramic slurry layer a refractory stucco to form a plurality of ceramic slurry layers and stucco layers on the pattern wherein at least one of the stucco layers is formed by applying discontinuous stucco fibers followed by applying a granular stucco particles on the discontinuous stucco fibers.

Abstract: A method of making a ceramic shell mold comprises repeatedly coating a fugitive pattern of an article to be cast with a ceramic slurry layer and applying on the ceramic slurry layer a refractory stucco to form a plurality of ceramic slurry layers and stucco layers on the pattern wherein at least one of the stucco layers is formed by applying discontinuous stucco fibers followed by applying a granular stucco particles on the discontinuous stucco fibers.

Abstract: The present invention relates to improvements in and relating to investment casting. In particular, the invention provides a method of investment casting, comprising the steps of mixing a binder, a refractory material, and a quantity of water-insoluble organic fibres to form a slurry; coating an expendable pattern with a coat of said slurry; and drying said coat or allowing said coat to dry to form a shell. The present invention further provides a refractory slurry for use in the method of the invention, and a kit of ingredients for putting the method of the invention into effect.

Abstract: A new mold solves problems that arise from differential changes in geometry inherent to casting metal in a ceramic mold, by control of the internal morphology between the surfaces of the mold that face the casting, and that face the external environment. Layered fabrication techniques are used to create a ceramic mold. For example, an internal geometry composed of a cellular arrangement of voids may be created within the mold wall. Structures may be designed and fabricated so that the ceramic mold fails at an appropriate time during the solidification and/or cooling of the casting. Thus, the casting itself is not damaged. The mold fails to avoid rupture, or even distortion, of the casting. A thin shell of ceramic defines the casting cavity. This shell must be thin enough to fail due to the stresses induced (primarily compressive) by the metal next to it and partly adherent to it.

Abstract: Method making a multi-wall ceramic core for use in casting airfoils, such as turbine blades and vanes, wherein a fugitive pattern is formed having multiple thin wall pattern elements providing internal wall-forming spaces of a final core, the pattern is placed in a core molding die cavity having a desired core configuration, a fluid ceramic material is introduced into the die cavity about the pattern and between the pattern elements to form a ceramic core, and the core is removed from the die cavity. The fugitive pattern is selectively removed from the core to provide a multi-wall green core. The green core then is fired to develop core strength for casting and used to form an investment casting mold for casting an airfoil.

Abstract: The invention relates to a investment casting molds and their method of manufacture. The method entails mixing refractory fiber, glass fiber, and refractory filler to form a dry blend; mixing the dry blend with an aqueous colloidal silica sol to form a refractory prime coat slurry, and employing the refractory slurry to produce an investment casting mold.

Abstract: The molding sand comprises hollow microspheres of aluminum silicate, preferably with an aluminum content between 15 and 45% by weight, a wall thickness between 3 and 10% of the particle diameter and a particle size between 10 and 350 &mgr;m. These sands are useful to manufacture low density cores with good “veining” and penetration characteristics, moreover maintaining the mechanical properties of the core obtained. These cores are useful in the manufacture of iron casting.

Abstract: A method of casting including forming a shell mold around a pattern fabricated from an expendable material and then removing the expendable material from the shell mold. The shell mold is located within a housing such that an inlet port of the shell mold communicates with an opening in the housing. A supporting material is provided and substantially fills an open volume between an external surface of the shell mold and an interior surface of the housing. A molten material is then pressure cast through the inlet port and into the shell mold. The invention includes a mold assembly and a casting system useful in practicing the disclosed method.