Abstract: A method of manufacturing a component includes additively manufacturing a crucible; directionally solidifying a metal material within the crucible; and removing the crucible to reveal the component. A component for a gas turbine engine includes a directionally solidified metal material component, the directionally solidified metal material component having been additively manufactured of a metal material concurrently with a core, the metal material having been remelted and directionally solidified.

Abstract: In a featured embodiment, a lost core assembly includes a ceramic component having a tapered shape in a radial direction. A refractory metal component extends radially from the ceramic core component. A method of molding a gas turbine engine component is also disclosed.

Abstract: A core assembly for forming a cast component includes a refractory metal core and a ceramic core element. The refractory metal core includes first and second ends and sides extending from the first end to the second end. The ceramic core element includes a slot positioned between first and second lands, each land having an inner surface facing the slot and an adjacent outer surface. The first end of the refractory metal core is secured within the slot with an adhesive, and the refractory metal core extends from the ceramic core element in both a longitudinal and a transverse direction. The slot, lands, and refractory metal core form a core assembly providing access paths to the sides of the refractory metal core. Surplus adhesive is removed from the refractory metal core via the access paths. Investment casting provides the component with an internal passage and an internal cooling circuit.

Abstract: A component casting apparatus includes a mold to receive a molten solid for casting a component. The mold includes a first sacrificial layer to define a housing of the component and a second sacrificial layer to form at least one core passage of the component in response to contact from the molten solid. The component casting apparatus further includes a trusset disposed against an outer surface of the second sacrificial layer and formed from metal to support the second sacrificial layer.

Abstract: An apparatus for casting material has a die for receiving a compressive force, the die having a shaped-opening for receiving a die insert. The die insert has an exterior shape that is adapted to cooperate with and be received in the opening such that compressive forces impinging upon the die are focused upon the die insert such that tensile forces within the die and impinging upon the die insert are minimized.

Abstract: A casting apparatus for casting a railcar coupler, which includes a shank portion and a head portion, includes cope and drag portions that define an external shape of the coupler. The casting apparatus also includes one or more cores that define an interior of the shank portion and a separate head core with an exterior that defines an interior of the head portion that includes lock chamber, guard arm side portion, and knuckle side portions of the head. The head core is a single piece with a hollow center section that defines a front face gating system that includes at least one in-gate configured to direct molten material to top and bottom regions of the head to define the lock chamber, guard arm side portion, and knuckle side of the head.

Abstract: The mold set is constructed with a cope, a drag, cheeks, and a core. In a case where the mold set is closed before molten metal is fed, a first clearance between a first mold (cope) that is located above a casting shape forming part of the core and the casting shape forming part is smaller than a second clearance between an upper surface of a core print of the core and a second mold (cheek) that is opposed to the upper surface.

Abstract: A core assembly for casting a railcar coupler knuckle includes a first core and a second core. The first core includes a lug. A slot is defined in the second core. First and second positive stop surfaces are provided. The invention reduces core shifting during casting and therefore improves the strength and fatigue life of a coupler knuckle.

Abstract: A rigging system for casting railcar coupler knuckles is provided. The rigging system comprises cope and drag portions of a mold, a down sprue defined in said cope portion, at least one riser defined in said mold, at least two ingates defined at least partially in said mold and connected to said at least one riser, at least two knuckle mold cavities defined in said mold, and wherein said ingates have a non-circular shape.

Abstract: A process for casting a turbine engine component is provided. The process comprises the steps of placing a refractory core assembly comprising two intersecting plates in a die, encapsulating the refractory core assembly in a wax pattern having the form of the turbine engine component, forming a ceramic shell mold about the wax pattern, removing the wax pattern, and pouring molten material into the ceramic shell mold to form the turbine engine component.

Abstract: A method for manufacturing a cylinder head system for a vehicle includes manufacturing a first main mold to integrally form an exhaust manifold for discharging exhaust gas from a cylinder and a first water jacket for cooling the exhaust manifold, manufacturing a second main mold to form a second water jacket for cooling a cylinder block, and connecting the first main mold to the second main mold. The mold includes a first main mold having a plurality of exhaust manifold molds and a first water jacket mold, each exhaust manifold mold being configured to form a respective exhaust manifold, and the first water jacket mold being configured to form a first water jacket for cooling the exhaust manifolds, a second main mold having a second water jacket mold, the second water jacket mold being configured to form a second water jacket for cooling a cylinder block, and the second main mold being configured to be assembled with the first main mold.

Abstract: A method for the casting of cast parts from an iron melt forming vermicular or spheroidal graphite, includes casting iron melt into a casting mold, which comprises at least one casting mold part, which is formed from a mold material, which is mixed from a sand-type basic material and an organic binder, and then gassed with a gas containing sulphur in order to harden the binder, such that a mold part of stable form is obtained. The method provides embodiments in which molds produced in accordance with the SO2 process enable the risk of occurrence of local microstructure degeneration in the cast part to be reduced to a minimum. This is achieved in that, after the hardening of the mold part and before the casting, at least one of the surfaces, which comes into contact with the iron melt, is provided with a coating containing a non-volatile sulphide former.

Abstract: The present invention relates to a casting mould for casting a casting, in particular an engine block for a combustion engine, as well as to the use of such a casting mould, comprising mould parts 1, 2, 3 and casting cores 4, 5, 6, 7 produced from moulding sand, and at least one casting core 4, 5, 6, 7 for the formation of a space in the casting. The casting mould according to the invention makes it possible, in a simple manner, for castings to be produced in which at least one locally closely confined section is formed with a microstructure which differs from the remainder of the casting. This is achieved in that a section of the casting core 4, 5, 6, 7 is formed by a chill 9 which is manufactured from a material of which the thermal conductivity is many times higher than the thermal conductivity of the other section 8 of the casting core 4, 5, 6, 7, consisting of moulding sand.

Abstract: A sand based mold and method for casting a device having a cavity. The sand based mold includes a core part including grains of sand bonded with a resin, where a shape of the core part fits a shape of the cavity of the device, and a first pipe embedded into the core part and configured to allow a compressed fluid to flow through the first pipe during a solidification process of the device, the first pipe having an inlet and an outlet that exit the mold.

Abstract: A casting core for a turbine blade includes a plurality of rods extending above a shank. The rods define internal cooling channels in the airfoil of the blade, and the shank defines an inlet channel in the dovetail of the blade. A plurality of stubs are clustered together at a bulb joined to the shank and radiate outwardly to integrally join different ones of the rods for increasing strength of the core.

Abstract: A disintegrative member, such as a salt core, is provided with a vent opening extending through its thickness from an outer surface to an inner surface in order to allow gases to pass radially inwardly through the body of the salt core and away from a region proximate the salt core's outer surface. The escape of these gases through the vent opening decreases the likelihood that porosity will be formed as a result of those gases being trapped in a region proximate the outer surface of the salt core because the molten metal solidifies more slowly in this area because of the thermal insulative qualities of the disintegrative member.

Abstract: An apparatus for casting an ingot includes a molten metal reservoir (51) positioned at an upper portion, a casting chamber (5) positioned at a lower portion and a partition wall (3) between the reservoir and the chamber, a spruce (7) formed in the partition wall, an opening/closing plug (8) for opening and closing the sprue and control means for controlling an opening and closing operation of the plug. The casing chamber is defined in a mold (1) that includes a lower mold member (4), a side mold member (2) and the partition wall (3) that constitutes an upper mold member. At least one of the lower mold member, side mold member and upper mold member includes a plurality of divided sections (21,22) in accordance with a shape of a cast ingot C.

Abstract: A sacrificial core for forming an interior space of a part includes a ceramic core element and a first core element including a refractory metal element. The ceramic core element may be molded over the first core element or molded with assembly features permitting assembly with the first core element.

Abstract: Flask-bound molds include two molding-flask halves, which have means (15) for the transport thereof on automatic mold systems. The molding flask receives a bound sand mold (8), which has cores (13), a pouring funnel (6) and a feeder passage (9). In order to be able to cast complicated castings also out of aluminum in such molds and to avoid the expensive finish work for the feeder and pouring funnel and in order to guarantee at the same time good core ventilation, the molding flask (4) has in the area of its parting plane a recess extending over at least a portion of the length and width of one side of the molding flask, whereby the pouring funnel (6) and the feeder (9) end in the area of the recess and the feeder is constructed within the sand mold (8) of the mold (1).

Abstract: A decomposable casting core (56a, 56b) is formed in-situ with a sleeve-like liner member (64) and the assembly mounted within the mold cavity (24) of a cylinder block casting mold (22) for lining piston cylinder chambers (62a, 62b) of a cylinder block (26) cast within the mold (22). The liner member (64) is formed with an inner annular recess (80) which receives a corresponding annular projection (76) of the core (56a, 56b) for preventing the liner (64) from sliding axially on the core (56a, 56b) during casting.

Abstract: A golf club metal wood head comprising a shell having a ball striking front face, a top wall, a bottom wall, and rear wall, and toe and heel walls, the combination comprising multiple ports in the bottom wall, the ports opening to the bottom wall exterior, and multiple inserts of different weight received into the ports from the exterior and connected to the bottom wall, the inserts having weights selected for golf club balance and swing adjustment.

Abstract: A sand casting core (102) for use in the manufacture of cast metal cylinder blocks includes a camshaft gallery-forming portion (108) and an interconnected oil gallery-forming portion (110) which is joined to the camshaft gallery-forming portion (108) via a plurality of transverse feeder passage-forming portions (112) extending therebetween for forming corresponding cast-in camshaft gallery (104) and interconnecting oil gallery (106) passages within a cast cylinder block (26).

Abstract: A method of eliminating solidification shrinkage porosity defects in cast metal articles includes disposing an expanded polystyrene chill (36) within a preformed mold cavity (26) and thereafter introducing molten metal into the cavity (26) and vaporizing the chill member (36), whereby the heat of vaporization rapidly cools a localized region of the molten metal adjacent the chill member and accelerates solidification thereof enabling remote still-molten metal to feed solidification shrinkage in this region and prevent the formation of porosity defects that would otherwise result.

Abstract: A golf club metal wood head comprising a shell having a ball striking front face, a top wall, a bottom wall, and rear wall, and toe and heel walls, the combination comprising multiple ports in the bottom wall, the ports opening to the bottom wall exterior, and multiple inserts of different weight received into the ports from the exterior and connected to the bottom wall, the inserts having weights selected for golf club balance and swing adjustment.

Abstract: A sleeve of woven heat resistant material is axially compressed (22) to enlarge its cross-sectional area and perimeter. A support element (24) is disposed within the sleeve (22) to support it in its enlarged perimeter condition (26). The sleeve-covered support element (18) is then disposed in a cavity (14) of a casting mold (12) and molten metal (36) is cast into the cavity (14) and around the sleeve-covered support element (18). The molten metal (36) is allowed to solidify to form a cast article (16). The support element (24) is then withdrawn from within the sleeve (22), leaving the sleeve (22) within and adhered to the walls of the passageway (20) of the article in the expanded perimeter condition (26). A tension force A is applied to the sleeve (22) forcing it to stretch into a smaller cross-sectional area and perimeter (28) and causing the sleeve (22) to detach from the casting (16) for easy removal.

Abstract: A closed mold for a cylinder head is provided having two widely spaced wall portions, at least one of the widely spaced wall portions being in communication with the atmosphere through an opening in the closed mold. The widely spaced wall portions define the ends of a long open cavity within the mold and provide core supporting portions for a long, narrow core element adapted to form an elongated, narrow open cavity within the casting. A narrow core element is provided between the core supporting portions of the widely spaced wall portions of the mold without intervening support. The long narrow core element comprises an outer portion of casting sand adapted to form the walls of the elongated, narrow open cavity of the casting extending between the core supporting portions. The narrow core element further comprises an inner portion for supporting the long, narrow core element and for providing a gas passage extending to the one wall portion.

Abstract: Method of and apparatus for making metal castings using a polystyrene pattern 10 embedded in unbonded sand 20 which is consolidated to form a mould M in which is defined a mould cavity C. Molten metal is fed into the cavity C and permitted to solidify to form a casting 11. The metal is aluminum or an aluminum alloy and at least part of the mould is formed of sand which comprises at least 50% zircon sand, or other particulate material suitable for making a mould and having a bulk density lying in the range 2-3 grams/cc. The mould M may have a moulding feature 9 having upper and lower surfaces for contact with the metal and which projects inwardly of the mould cavity C from the main wall thereof and the length of any one section of the molding feature 9 being at least twice the thickness of the thinnest part thereof by which the section is connected to the main wall of the mould cavity.

Abstract: Apparatus for the countergravity, shell-mold casting process comprising a gas-permeable shell mold sealed in the mouth of a vacuum chamber and a hollow, expendable, gas-permeable, thermally degradable, core disposed with the molding cavity for engulfment and retention by the metal being cast. The core defines a central evacuation cavity and an unobstructed vent for exhausting the evacuation cavity into the vacuum chamber such that the pressure in the evacuation cavity is substantially equal to that in the vacuum chamber during casting.

Abstract: A mold producing one or more globe-shaped bells, each of which is cast as a one-piece shell enclosing a tumbling ball-bearing or jinglet. Production of the one-piece shell is made possible by pouring molten metal over a spherical core, supported by small "feet" inside the globe-like cavity of the mold. When the shell is removed from the mold, the core, in which the ball-bearing or jinglet is embedded, can easily be disintegrated or broken down into particles which fall out holes in the shell's surface.

Abstract: Disclosed is a core for producing halves of cambered hollow articles, such as bonded turbine blades. The core has opposing flanges which differ in thickness, since the opposing contour surfaces are rotated relative to one another, compared to the relationship of the contour surfaces in the interior of the hollow article being produced. Thus, the core is made thicker and more sound in the area of high camber where it is otherwise prone to be thin.

Abstract: A mold producing one or more globe-shaped bells, each of which is cast as a one-piece shell enclosing a tumbling ball-bearing or jinglet. Production of the one-piece shell is made possible by pouring molten metal over a spherical core, supported by small "feet" inside the globe-like cavity of the mold. When the shell is removed from the mold, the core, in which the ball-bearing or jinglet is embedded, can easily be broken down into particles which fall out holes in the shell's surface.

Abstract: A novel casting method is provided which includes a shell mold having a cope and a drag, which abut together along substantially planar mating surfaces and define a casting cavity between the cope and drag. At least one core is positioned within the casting cavity and includes at least one and preferably two crush pads each having a cam surface. As the cope is positioned onto the drag, the cope engages the crush pad cam surfaces and cams the core flatly against the shell mold.

Abstract: A machine for forming foundry moulds includes a turret supporting spaced mould frames, each of the latter having a mould portion formed therein by rotation of the turret toward a sand filling and compacting station and away therefrom. The completed mould portion may be moved to a position where a core can be set thereon and then moved to a position where the mould portions are positioned one atop another to make a stack of finished and cored moulds. When the moulds are not cored, a pair of said filling and compacting stations are provided, the turret oscillating or rotating unidirectionally from a loading position to a delivery position. Where a pair of filling and compacting stations are provided for forming cope and drag mould portions, the turret oscillates to place the two mould portions in proper position to form a mould comprised of cope and drag portions.

Abstract: An ingot mold has been devised which instead of utilizing a full protective thickness or section of sand within the spacing between a metal core bar and a metal flask, employs a refractory lining for the flask and a refractory coat for the bar that respectively have a cross extent or thickness that occupies a greater portion of the spacing than the casting sand. The casting sand is utilized as a minimum inner thickness to define the casting mold and as imposed between the refractory lining and coat.

Abstract: In the manufacture of hollow turbine blades or vanes especially those having a columnar crystalline growth in the alloy, the blade is cast in two opposed halves against a central mold element, the latter being rigid enough to avoid deformation during heating of the mold prior to pouring and during solidification. This central element has on opposite surfaces the configurations of the inner surfaces of the hollow blade. Cooperating with this inner element are outer elements having cooperating inner surface configurations of the convex and concave sides of the blade respectively. After the blade halves are cast simultaneously in the assembled mold and removed therefrom they are bonded together to form a complete blade.

Abstract: A method of making a brake shoe having a curved table section and at least one rib section disposed on the concave side of the table section, generally including casting the brake shoe in a mold having cope and drag sections so that the axis of curvature of the table section thereof is disposed substantially parallel to the parting plane of the mold sections whereby no draft or parting ridge is formed on the outer curved surface of the table section.