Abstract: Method for manufacturing a gas burner of the type comprising a cup, provided with at least one tubular tapered part of a mixer with axial Venturi effect, and shaped to couple with a burner head provided with at least one flame-spreader, wherein said cup is made in a single piece by casting or die-casting in an apposite mold.

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 core for casting a container includes a casting surface, where the core is divided into at least two core segments. The casting surface of each core segment adjoins a division surface, and the division surface of each core segment is spaced apart from the division surface of a neighboring core segment by a gap. The gap is spanned by a frangible collapsible member such that substantially all of the casting surface is free of the collapsible member.

Abstract: A coring system for producing a flash-free one-piece die-cast body for an electrical connector. The electrical connector of produced by the coring system of the present invention may be used for securing two electrical cables to an electrical panel or electrical box through a single knockout hole. The coring system includes a first core, a second core, and a connecting arrangement for connecting the first and second cores in such a manner that there are no gaps between the joined portions of the two cores. When the cores of the coring system are joined together by the connecting arrangement and placed in a mold, molten metal may be introduced to the mold at the joined area of the two core pieces to form a one-piece flash-free connector body according to the present invention.

Abstract: A coring system for producing a flash-free one-piece die-cast body for an electrical connector. The electrical connector of produced by the coring system of the present invention may be used for securing two electrical cables to an electrical panel or electrical box through a single knockout hole. The coring system includes a first core, a second core, and a connecting arrangement for connecting the first and second cores in such a manner that there are no gaps between the joined portions of the two cores. When the cores of the coring system are joined together by the connecting arrangement and placed in a mold, molten metal may be introduced to the mold at the joined area of the two core pieces to form a one-piece flash-free connector body according to the present invention.

Abstract: Disclosed is a mold for casting multiple castings in sand including a flaskless mold and a core assembly. The core assembly is within the flaskless mold with the sand surrounding the core assembly. The core assembly can have a central axis, a plurality of window cores and at least two splitter cores. The plurality of window cores and the at least two splitter cores are alternately stacked to form a plurality of casting cavities along the central axis. In some instances, two of the plurality of window cores are mirror-image oriented with respect to each other along the central axis and two of the plurality of window cores are oriented the same with respect to each other along the central axis.

Abstract: Knuckle coupler castings and methods for casting the knuckle coupler castings, where the knuckle coupler castings having enhanced bearing surfaces which may include a vertically flat surface.

Abstract: A method for manufacturing a railcar coupler knuckle includes providing a cope mold portion and a drag mold portion. The cope and drag mold portions have internal walls defining at least in part perimeter boundaries of a coupler knuckle mold cavity. The method includes positioning one or two internal cores within either the cope mold portion or the drag mold portion. The one or two internal cores are configured to define a kidney cavity, a finger cavity and a pivot pin cavity of a coupler knuckle. The method includes closing the cope and drag mold portions with the one or two internal cores therebetween and at least partially filling the mold cavity with a molten alloy, the molten alloy solidifying after filling to form the coupler knuckle.

Abstract: An airfoil, a method of manufacturing an airfoil, and a system for cooling an airfoil is provided. The cooling system can be used with an airfoil located in the first stages of a combustion turbine within a combined cycle power generation plant and involves flowing closed loop steam through a pin array set within an airfoil. The airfoil can comprise a cavity having a cooling chamber bounded by an interior wall and an exterior wall so that steam can enter the cavity, pass through the pin array, and then return to the cavity to thereby cool the airfoil. The method of manufacturing an airfoil can include a type of lost wax investment casting process in which a pin array is cast into an airfoil to form a cooling chamber.

Abstract: An engine block mold package includes a barrel crankcase core having a plurality of barrels on each of which a respective cylinder bore liner is disposed. Each cylinder bore liner includes an inside diameter that is tapered along at least a portion of its length to match a draft angle present on the barrels to permit removal of the barrel crankcase core from a core box in which it is formed.

Abstract: An integral ceramic casting core includes a base portion with a plurality of rods extending therefrom and a plurality of apertures formed therein. The base portion defines a passageway for the passage of a cooling media within a cast component. The plurality of rods forming cooling media inlet passages to the passageway and the plurality of apertures are adapted to receive molten metal therein and form heat transfer pedestals within the passageway.

Abstract: An engine block mold package is assembled from resin-bonded sand cores in a manner that reduces parting lines on the exterior surfaces of the mold package. An assembly of multiple cores (core package) is formed and includes multiple inter-core parting lines extending in different directions on exterior surfaces of the core assembly. The core package is disposed between a base core and a cover core configured to enclose the core package and form a single continuous exterior parting line about the assembled mold package.

Abstract: In assembly of engine block mold package, a water jacket slab core is assembled on a barrel crankcase core having a plurality of barrels on which cylinder bore liners are positioned. Some of the barrels include a core print on a distal end thereof. The water jacket slab core includes a plurality of core prints each in mating relation with a respective barrel core print and a plurality of bore liner positioning surfaces that each engage a respective distal end of a respective cylinder bore liner when the water jacket slab core is assembled on the barrels.

Abstract: A cast product is a housing for a power steering comprising a pair of large holes for both a contact valve and a cylinder, and a small hole connected to the large holes. In order to mold such a cast product, a composite core has large core portions for the large holes and small core portions for the small hole. The large core portions include resin films used to coat the outer periphery of metal bases exposed in a cavity. The small core portions include a resin body formed of a resin connected to the resin films on the outer periphery of the metal bases.

Abstract: A process for inserting cores into a casting mold includes inserting a plurality of individual cores into a template; forming a core group by joining together the plurality of individual cores within the template using a bracing and securing device which is detachable; dipping the core group into a founder's black bath to provide a coated core group; drying the coated core group; inserting the core group after drying into the casting mold; and removing the bracing and securing device. The process advantageously additionally includes providing a plurality of core groups that form a core assembly for a casting mold; forming a core set by joining together the plurality of core groups using a bracing and securing device; dipping the core set into a founder's black bath to provide a coated core set; drying the coated core set; inserting the core set after drying into the casting mold; and removing the bracing and securing device.

Abstract: A plurality of inter-connected cores includes barrel cores (18). Bore liners (10) surround the barrel cores (18) and are fixed in relation thereto. A cylinder block mold core package (22) is assembled from the cores (14, 24, 26, 28). The liners (10) are heated while they are within the cylinder block mold core package (22) by induction heating. To prevent migration, a mechanical interlock is provided between each liner (10) and its associated barrel core (18).

Abstract: A one-piece cylinder head casting, including reliably located passageways for fuel-air intake, for exhaust and for coolant, is formed by a plurality of interengaging one-piece core elements including a one-piece coolant jacket core, a one-piece exhaust core and a one-piece fuel-air intake core, all reliably positioned and held together in an integral core assembly. Preferably, a further core element having a plurality of core supporting and positioning surfaces provides surfaces that mate interfacing surfaces of the one-piece water jacket core, one-piece exhaust core and one-piece intake core and support such cores in position with respect to one another, and the intake core may be provided with a plurality of interfacing surfaces to lock the plurality of core elements into a unitary core assembly. Such cylinder head casting may also be provided with integral walls forming a long, open intake manifold cavity in the side of the cylinder head.

Abstract: A reinforced tubular core for casting gas turbine engine blades with cooling air passages therein is disclosed. A method of casting is also disclosed in which the blades are directionally solidified to produce columnar grained or single crystal blades and in which non-linear passages can be produced. The problem in producing such articles is that the moulds and cores used in the casting process are held at temperatures in excess of 1500.degree. for long periods and presently used silica cores deform during the process. Stronger cores of alumina or silicon nitride cannot be easily bent were believed to be non-leachable from the casting. The present invention provides a core having a tubular silica sheath with a solid alumina rod inside it for support. The sheath can be bent and the straight alumina rods can be inserted from opposite ends of the sheath.

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: 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: Hand patching of recesses in the side walls of a sand mold, intended to receive a core, is avoided by filling the recess, after the core is emplaced with a complemental pre-molded cover.

Abstract: A novel core assembly is used in a sand mold for casting a hollow section in a coupler head extending beyond a horn line into a coupler shank of a coupler for a railway vehicle. The core assembly includes head and shank core members having face surfaces each including a recess surface and a projected surface arranged such that the recess surface in the head core receives the projected surface in the shank core. In a similar way, the recess surface in the shank core receives the projected surface in the head core to maintain the head and shank cores in an aligned abutting relation while supported in the sand mold. The face surfaces extend transversely to the coupler shank along a parting line spaced rearwardly of the plane containing the horn line of the coupler. The face surfaces are further characterized by a conically-shaped projection extending from one core member into a conically-shaped opening in the other core member to mechanically interconnect and align the two core members.

Abstract: The drag pattern for a standard AAR coupler is modified to increase the thickness of the bottom wall of a coupler casting forwardly and rearwardly of a plane containing the horn line. The increased thickness is achieved by forming a substantially planar bottom wall surface for a distance of at least two inches at either side of a plane containing the horn line. Head and shank pattern parts are interchangeable and releasably secured onto a pattern plate for molding foundry sand in the drag portion of a foundry mold to produce E, E/F and F-types of coupler castings.

Abstract: A die-cast peripheral housing for the rotor of rotary combustion engines, having cast-in passages for liquid cooling, the passages providing optimum wall thickness and coolant flow at the region of high heat input.