Core Patents (Class 164/369)
  • Patent number: 10400609
    Abstract: An airfoil includes leading and trailing edges; first and second sides extending from the leading edge to the trailing edge, each side having an exterior surface; a core passage located between the first and second sides and the leading and trailing edges; and a wall structure located between the core passage and the exterior surface of the first side. The wall structure includes a plurality of cooling fluid inlets communicating with the core passage for receiving cooling fluid from the core passage, a plurality of cooling fluid outlets on the exterior surface of the first side for expelling cooling fluid and forming a cooling film along the exterior surface of the first side, and a plurality of cooling passages communicating with the plurality of cooling fluid inlets and the plurality of cooling fluid outlets. At least a portion of one cooling passage extends between adjacent cooling fluid outlets.
    Type: Grant
    Filed: January 9, 2018
    Date of Patent: September 3, 2019
    Assignee: United Technologies Corporation
    Inventors: Eric A. Hudson, Tracy A. Propheter-Hinckley, San Quach, Matthew A. Devore
  • Patent number: 10307816
    Abstract: A core for use in casting an internal cooling circuit within a gas turbine engine component includes a base core portion and an additive core portion additively manufactured to the base core portion. A method of manufacturing a core for use in casting an internal cooling circuit within a gas turbine engine component including additively manufacturing an additive core portion to a base core portion.
    Type: Grant
    Filed: October 26, 2015
    Date of Patent: June 4, 2019
    Assignee: United Technologies Corporation
    Inventors: Thomas N Slavens, James Tilsley Auxier
  • Patent number: 10252328
    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.
    Type: Grant
    Filed: October 12, 2016
    Date of Patent: April 9, 2019
    Assignee: United Technologies Corporation
    Inventor: Tracy A. Propheter-Hinckley
  • Patent number: 10052686
    Abstract: A method for the production of castings which are permanently provided with readable information. An identification element, which has an information surface, provided with information, and a casting surface which is assigned to the casting and also provided with information, is arranged on a casting mould surface assigned to a mould cavity of a casting mould so that the information surface is covered, while the casting surface is exposed in the mould cavity. A metal melt is poured into the mould, so that, during casting or solidification of the metal melt, a firmly bonded, form-fit or force-fit connection of the identification element to the casting is produced. The information on the casting surface is reproduced in the manner of a stamp on surface of the casting. The casting is then removed from the mould and fettled.
    Type: Grant
    Filed: February 2, 2016
    Date of Patent: August 21, 2018
    Assignee: Nemak, S.A.B. de C.V.
    Inventors: Thorsten Behr, Matthias Ghodstinat
  • Patent number: 10040116
    Abstract: There is provided a manufacturing method including: forming a molded body element with a molding material containing a ceramic powder and a binder; forming a ceramic molded body by disposing at least one molded body element in a mold and then injecting a molding material containing a ceramic powder and a binder into the mold and graft molding a graft molded body element to the molded body element; and forming a ceramic sintered body by degreasing and sintering the ceramic molded body. A graft connecting surface of the molded body element to which the graft molded body element is graft molded is formed so as to have a surface roughness of 2 ?m or more in terms of Ra.
    Type: Grant
    Filed: February 12, 2015
    Date of Patent: August 7, 2018
    Assignee: HITACHI METALS, LTD.
    Inventors: Hideko Fukushima, Masayoshi Date, Tsuyoshi Yamamoto, Shuhei Iwagaki
  • Patent number: 9957813
    Abstract: A gas turbine engine blade includes a platform arranged between a root and an airfoil. A cooling passage extends from the root through the platform to the airfoil. The cooling passage includes an inlet that splits into first and second branches that rejoin one another in a platform passage arranged in the platform. An airfoil passage extends from the platform passage and is arranged in the platform.
    Type: Grant
    Filed: February 5, 2014
    Date of Patent: May 1, 2018
    Assignee: UNITED TECHNOLOGIES CORPORATION
    Inventor: Brandon W. Spangler
  • Patent number: 9539639
    Abstract: A ceramic core is obtained by firing a mixture that contains 0.1-15.0% by mass of alumina and 0.005-0.1% by mass of potassium and/or sodium with the balance made up of silica and unavoidable impurities. Not less than 90% by mass of amorphous silica is contained in 100% by mass of the silica. A method for producing a ceramic core, wherein: a blended material is obtained by blending 25-45% by volume of a binder into 55-75% by volume of a mixture that is obtained by mixing alumina, potassium and/or sodium, and silica so as to have the above-mentioned composition; the blended material is injected into a die so as to obtain a molded body; and the molded body is degreased at 500-600° C. for 1-10 hours, and then fired at 1,200-1,400° C. for 1-10 hours.
    Type: Grant
    Filed: February 28, 2012
    Date of Patent: January 10, 2017
    Assignee: HITACHI METALS, LTD.
    Inventor: Hideko Fukushima
  • Patent number: 9486853
    Abstract: A casting mold assembly includes an airfoil defining section and a casting core. The airfoil defining section includes an outer mold wall and a direct-shelled inner mold wall. The direct-shelled inner mold wall is disposed within a forward chordwise portion of the airfoil defining section. The direct-shelled inner mold wall includes an aft end having an external radius measuring more than about 0.075 in. (1.9 mm). The casting core is secured within an aft chordwise portion of the airfoil defining section, and includes an aft end with an external radius measuring less than about 0.075 in. (1.9 mm). A cast component and a method for making the casting mold assembly are also disclosed.
    Type: Grant
    Filed: September 14, 2012
    Date of Patent: November 8, 2016
    Assignee: United Technologies Corporation
    Inventors: Steven J. Bullied, Carl R. Verner, Steven D. Porter, James B. Park
  • Patent number: 9314839
    Abstract: Provided in an embodiment is a method for molding, including: providing a molten alloy in a space between a mold cavity and an etchable block shaped to form an undercut on a part formed in the space, cooling the molten alloy to form the part with the undercut, and etching the etchable block. An undercut is a beveled edge caused by an etchant attacking an etchable block laterally and optionally vertically. The formed part can be made of a bulk amorphous alloy. In some cases, the etchable block can also be used to form at least one threaded portion in the part.
    Type: Grant
    Filed: July 5, 2012
    Date of Patent: April 19, 2016
    Assignee: Apple Inc.
    Inventors: Christopher D. Prest, Matthew S. Scott, Stephen P. Zadesky, Dermot J. Stratton, Joseph C. Poole
  • Patent number: 9038706
    Abstract: A method of forming a cast product (30) by providing a core (52) having a plurality of sections (54) and one or more gaps (55) there-between. The core further includes an insert member (60) spanning the gap (55) between adjacent sections (54). The core (52) is located within a mold (68) and a liquid phase material is introduced into gap (55) between the core sections. The liquid phase material is solidified in the gap so as to form a cast feature of a resulting solid product and the core sections (54) are removed from the solid product (30) such that the insert member (60) remains securely held within the feature (74).
    Type: Grant
    Filed: November 24, 2010
    Date of Patent: May 26, 2015
    Assignee: ROLLS-ROYCE PLC
    Inventor: Steven M. Hillier
  • Publication number: 20150129155
    Abstract: The invention relates to a method for producing casting molds and cores, in which a foundry base material comprising at least one refractory material and a binder curable by CO2, preferably based on water glass, is cured by gassing with CO2 and flushing with a second gas. The invention further relates to molds and cores produced according to this method.
    Type: Application
    Filed: April 26, 2013
    Publication date: May 14, 2015
    Inventors: Diether Koch, Oliver Schmid
  • Publication number: 20150118057
    Abstract: A multi-wall gas turbine airfoil (192) and method of forming same using a casting core (150) having a monolithic body configured to define a pressure side wall (12), a suction side wall (14), and a third wall (16). The casting core is formed around a fugitive insert (96) during a single pour casting process.
    Type: Application
    Filed: October 31, 2013
    Publication date: April 30, 2015
    Inventors: Ching-Pang Lee, Gary B. Merrill
  • Publication number: 20150096711
    Abstract: A composite core for forming a passage in an investment casting mold is provided including a core element. A generally hollow structural element is positioned about an exterior of the core element. The structural element is configured to deform when a force is applied to the structural element. A rigid shell element is integrally formed about the structural element. The shell element is configured to break when the structural element deforms.
    Type: Application
    Filed: October 7, 2013
    Publication date: April 9, 2015
    Applicant: Sikorsky Aircraft
    Inventors: Jonathan Bremmer, Shihong G. Song, Jeffrey G. Sauer, James S. Giampapa
  • Patent number: 8997836
    Abstract: A multi-wall ceramic core for casting an airfoil with one or more internal cooling passages is made by preforming at least one fugitive core insert to have a joint-forming surface with a male and/or female joint feature and then forming at least one fugitive core insert in-situ adjacent and integrally connected and fused to the at least one preformed core insert at the joint-forming surface to form an interlocked, fused joint to form a composite core insert that includes features to form internal passage surfaces in the core when the composite core insert is removed. Another aspect involves preforming first and second fugitive core inserts to have respective joint-forming surfaces with respective snap-fittable joint features and assembling the first and second fugitive core inserts to form a composite core insert by snap fitting the snap-fittable joint features together to form an interlocked joint.
    Type: Grant
    Filed: October 21, 2014
    Date of Patent: April 7, 2015
    Assignee: Howmet Corporation
    Inventors: Boyd A. Mueller, Darren K. Rogers, Timothy J. Molamphy
  • Patent number: 8985188
    Abstract: Disclosed is a cast pin equipped with circular grooves which are provided at any location. The cast pin (10) is equipped with: an outer tube (11) in the shape of a hollow body the tip of which is closed; an inner tube (20) inserted into the outer tube (11); and a cooling medium pipe (30) that is inserted into the inner tube (20) and supplies a cooling medium to the interior of the inner tube (20). Three circular grooves (22) are formed at prescribed intervals in the longitudinal direction, for example, on the outer circumferential surface (21) of the inner tube (20). The circular grooves (22) are formed in the outer circumferential surface (21) by applying a cutting tool from the radial outward direction of the inner tube (20).
    Type: Grant
    Filed: February 29, 2012
    Date of Patent: March 24, 2015
    Assignee: Honda Motor Co., Ltd.
    Inventors: Kiyoshi Shibata, Akihiro Ikegami, Masayuki Numata
  • Publication number: 20150078912
    Abstract: The disclosure relates generally to core compositions and methods of molding and the articles so molded. More specifically, the disclosure relates to core compositions and methods for casting hollow titanium-containing articles, and the hollow titanium-containing articles so molded.
    Type: Application
    Filed: September 18, 2013
    Publication date: March 19, 2015
    Applicant: GENERAL ELECTRIC COMPANY
    Inventors: Bernard Patrick BEWLAY, Joan MCKIEVER, Brian Michael ELLIS, Nicholas Vincent MCLASKY
  • Publication number: 20150072163
    Abstract: A ceramic core includes sintered ceramic powder and a hole opening on a surface of the ceramic core and having an opening portion with a maximum size of 100 ?m or less. A manufacturing method for a ceramic core includes: preparing an injection molding composition by mixing ceramic powder and a binder; manufacturing a ceramic compact by performing the injection molding of the injection molding composition; and manufacturing a ceramic core by sintering the ceramic compact, wherein cumulative percentage of coarse powder with a particle diameter of more than 50 ?m included in the ceramic powder is 30% or less on an integrated volume particle size distribution curve of the ceramic powder.
    Type: Application
    Filed: September 2, 2014
    Publication date: March 12, 2015
    Inventor: Hideko FUKUSHIMA
  • Publication number: 20150060005
    Abstract: Cores that are inserted into the mold during the die casting of workpieces from metal in order to keep the cavities provided in the workpieces free during the filling of the molds with the melt have to meet demanding requirements with regard to the dimensional stability and suitability thereof for removal from the cavities. Therefore, salt-based cores which can be produced by molding and compressing a core material mixture are provided according to the invention, the core materials thereof being selected from at least one salt, at least one binder system comprising a combination of binder/binding agent and optionally auxiliary substances such as additives, fillers, wetting agents and catalysts, wherein the salt, the binder system and the optionally used auxiliary substances of the core material mixture are inorganic, and these core materials are soluble with water as the solvent.
    Type: Application
    Filed: April 10, 2013
    Publication date: March 5, 2015
    Applicant: Emil Müller GmbH
    Inventor: Thorsten Hartig
  • Patent number: 8955576
    Abstract: A core assembly for a turbine engine blade includes a generally radially extending trunk interconnected to multiple generally axially extending tabs. The tabs are interconnected by a generally radially extending ligament. Multiple generally axially extending protrusions are interconnected to the ligament opposite the trunk. A mold is configured to define an exterior surface of an airfoil. The core is arranged within the mold and is configured such that the tabs and the ligament break through at the exterior surface.
    Type: Grant
    Filed: January 15, 2014
    Date of Patent: February 17, 2015
    Assignee: United Technologies Corporation
    Inventors: Jason Edward Albert, Atul Kohli, Eric L. Couch
  • Patent number: 8944141
    Abstract: A core for forming a cooling microcircuit has at least one row of metering/tripping features configured to form at least one row of protrusions in the cooling microcircuit, a plurality of teardrop features configured to form a plurality of fluid passageways in the cooling microcircuit, and a terminal edge. The plurality of teardrop features includes a central teardrop feature having a trailing edge which is spaced from the terminal edge and a first teardrop feature located on a first side of and spaced from the central teardrop feature. The first teardrop feature has a longitudinal axis and is non-symmetrical about the longitudinal axis. A process of using the core and a turbine engine component formed thereby are described.
    Type: Grant
    Filed: December 22, 2010
    Date of Patent: February 3, 2015
    Assignee: United Technologies Corporation
    Inventors: Tracy A. Propheter-Hinckley, Stephanie Santoro
  • Publication number: 20150027658
    Abstract: A hybrid ceramic/sand casting method of manufacturing a metal part. The method is especially suitable for manufacturing engine cylinder blocks or cylinder head, which have very small internal passages or other very small internal features. These parts are formed using a hybrid core having at least one ceramic section and at least one sand section, with the ceramic section being used to create the internal feature. A mold cavity is created for the part, and the hybrid core is positioned in the mold. Molten metal is introduced into the mold, and after the metal cools, the core is removed, thereby forming the part with the internal feature.
    Type: Application
    Filed: July 23, 2013
    Publication date: January 29, 2015
    Applicant: Southwest Research Institute
    Inventors: Barry E. Westmoreland, Douglas A. McKee, Marc C. Megel, Mark A. Tussing, Thomas E. Reinhart, David P. Branyon
  • Patent number: 8936068
    Abstract: A method of casting a component (42) having convoluted interior passageways (44). A desired three dimensional structure corresponding to a later-formed metal alloy component is formed by stacking a plurality of sheets (18, 20) of a fugitive material. The sheets contain void areas (22) corresponding to a desired interior passageway in the metal alloy component. A ceramic slurry material is cast into the three dimensional structure to form either a ceramic core (34) or a complete ceramic casting vessel (38). If just a ceramic core is formed, a wax pattern is formed around the ceramic core and an exterior ceramic shell (38) is formed around the wax pattern by a dipping process prior to the removal of the fugitive material and wax. An alloy component having the desired interior passageway is cast into the casting vessel after the fugitive material is removed.
    Type: Grant
    Filed: April 15, 2011
    Date of Patent: January 20, 2015
    Assignees: Siemens Energy, Inc., Mikro Systems, Inc.
    Inventors: Ching-Pang Lee, Gary B. Merrill, Andrew J. Burns
  • Patent number: 8936067
    Abstract: A ceramic casting core, including: a plurality of rows (162, 166, 168) of gaps (164), each gap (164) defining an airfoil shape; interstitial core material (172) that defines and separates adjacent gaps (164) in each row (162, 166, 168); and connecting core material (178) that connects adjacent rows (170, 174, 176) of interstitial core material (172). Ends of interstitial core material (172) in one row (170, 174, 176) align with ends of interstitial core material (172) in an adjacent row (170, 174, 176) to form a plurality of continuous and serpentine shaped structures each including interstitial core material (172) from at least two adjacent rows (170, 174, 176) and connecting core material (178).
    Type: Grant
    Filed: October 23, 2012
    Date of Patent: January 20, 2015
    Assignees: Siemens Aktiengesellschaft, Mikro Systems, Inc.
    Inventors: Ching-Pang Lee, Benjamin E. Heneveld
  • Publication number: 20150017014
    Abstract: A core (10) for casting a hollow component of a turbomachine. The core includes a first portion (12) for providing a shape to the component and a second portion (14) located outside of the component. The second portion (14) comprises a plurality of indentations (16) for preventing a breakage of the core (10) at a region proximal to the first portion (14).
    Type: Application
    Filed: December 18, 2012
    Publication date: January 15, 2015
    Inventors: Fathi Ahmad, Uwe Paul
  • Patent number: 8915289
    Abstract: A multi-wall ceramic core for casting an airfoil with one or more internal cooling passages is made by preforming at least one fugitive core insert to have a joint-forming surface with a male and/or female joint feature and then forming at least one fugitive core insert in-situ adjacent and integrally connected and fused to the at least one preformed core insert at the joint-forming surface to form an interlocked, fused joint to form a composite core insert that includes features to form internal passage surfaces in the core when the composite core insert is removed. Another aspect involves preforming first and second fugitive core inserts to have respective joint-forming surfaces with respective snap-fittable joint features and assembling the first and second fugitive core inserts to form a composite core insert by snap fitting the snap-fittable joint features together to form an interlocked joint.
    Type: Grant
    Filed: March 13, 2013
    Date of Patent: December 23, 2014
    Assignee: Howmet Corporation
    Inventors: Boyd A. Mueller, Darren K. Rogers, Timothy J. Molamphy
  • Publication number: 20140352910
    Abstract: The subject matter of the invention relates to sizing compositions as coating compositions for casting molds. The sizing composition is suitable for cores and molds, in particular those produced using water glass as a binder. The sizing composition contains certain salts.
    Type: Application
    Filed: October 5, 2012
    Publication date: December 4, 2014
    Inventors: Michael Kloskowski, Peter Wachtarczyk, Carolin Wallenhorst, Stefan Bezold
  • Patent number: 8899303
    Abstract: A multi-wall ceramic core for casting an airfoil with one or more internal cooling passages is made by preforming at least one fugitive core insert, then forming at least one core insert in-situ adjacent and fused to the at least one preformed core insert by introducing fluid fugitive pattern material into a composite core insert mold whereby the fugitive core inserts are integrally connected as a single composite core insert that includes features to form internal passage surfaces in the core when the composite core insert is removed. The composite core insert is placed in a core molding die cavity, and a fluid ceramic material is introduced into the die cavity to form the ceramic core body incorporating the fugitive composite core insert therein.
    Type: Grant
    Filed: May 10, 2011
    Date of Patent: December 2, 2014
    Assignee: Howmet Corporation
    Inventors: Boyd Mueller, Darren Rogers, Timothy J. Molamphy
  • Patent number: 8893767
    Abstract: A multi-wall ceramic core for casting an airfoil with one or more internal cooling passages is made by preforming at least one fugitive core insert, then forming at least one core insert in-situ adjacent and fused to the at least one preformed core insert by introducing fluid fugitive pattern material into a composite core insert mold whereby the fugitive core inserts are integrally connected as a single composite core insert that includes features to form internal passage surfaces in the core when the composite core insert is removed. The composite core insert is placed in a core molding die cavity, and a fluid ceramic material is introduced into the die cavity to form the ceramic core body incorporating the fugitive composite core insert therein.
    Type: Grant
    Filed: September 19, 2012
    Date of Patent: November 25, 2014
    Assignee: Howmet Corporation
    Inventors: Boyd Mueller, Darren Rogers, Timothy J. Molamphy
  • Publication number: 20140319092
    Abstract: A method of casting a core includes the steps of preparing a first half of a corebox, preparing a second half of a corebox such that the parting line of a core formed from the first and second coreboxes runs along the vertical axis of the core.
    Type: Application
    Filed: May 5, 2014
    Publication date: October 30, 2014
    Applicant: BEDLOE INDUSTRIES LLC
    Inventors: F. Andrew Nibouar, Jerry R. Smerecky, Kelly Day, Vaughn Makary, Nick Salamasick
  • Patent number: 8851151
    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.
    Type: Grant
    Filed: March 25, 2005
    Date of Patent: October 7, 2014
    Assignee: Rolls-Royce Corporation
    Inventors: Donald J. Frasier, Matthew Kush, Max Eric Schlienger, Michael Baldwin
  • Publication number: 20140251571
    Abstract: A casting core resulting from alkaline earth metal oxide particles having an average particle size of 0.8-4 mm being dispersed in a water-soluble alkali metal salt matrix. The casting core can be efficiently produced using a method of dispersing alkaline earth metal hydroxide particles having favorable disintegration properties and a particle size in the range of 1-5 mm in a molten water-soluble alkali metal salt, converting to alkaline earth metal oxide particles by means of dehydration, and casting in a mold, cooling, and hardening.
    Type: Application
    Filed: October 10, 2012
    Publication date: September 11, 2014
    Inventors: Takafumi Kotani, Yuichi Mizumura, Hikotaro Suzuki, Masaya Nomura
  • Patent number: 8820389
    Abstract: A method for the high pressure die casting of an engine block assembly having at least one cast in place cylinder bore in the engine block and a closed head deck surface, and the resultant engine block are disclosed. This closed deck high pressure die cast engine block assembly will preferably have at least two cast in place cylinder bores in the engine block formed by using a composite core of salt core material supported by at least one cylinder bore to be cast in place. The cylinder bores have a lower outer surface preferably defining at least one surface area that interfaces with the engine block during casting such that the at least one cylinder is cast in place in the engine block. An engine block water jacket—as defined by the salt core portion of the composite core—will preferably provide an open passage between each cylinder bore such that water may flow around and entire outer circumference of the upper outer surface of the cylinder bores.
    Type: Grant
    Filed: October 31, 2012
    Date of Patent: September 2, 2014
    Assignee: Brunswick Corporation
    Inventor: Mark T. Degler
  • Publication number: 20140238632
    Abstract: A method is provided for repairing defects in a ceramic core adapted for use in a casting process. The ceramic core is formed from a slurry comprising at least one refractory powder material suspended in a liquid vehicle. The method includes forming a repair mixture comprising a liquid diluent and the at least one refractory powder material suspended in the liquid vehicle of the slurry. The repair mixture is applied to a region of the ceramic core that includes at least one defect and then the ceramic core is fired to burn off the liquid vehicle in the repair mixture and form a ceramic composition that closes the defect.
    Type: Application
    Filed: February 28, 2013
    Publication date: August 28, 2014
    Applicant: GENERAL ELECTRIC COMPANY
    Inventors: Xi Yang, Martin Kin-Fei Lee, Sylvia Marie Decarr, Norbert Otto Maurer
  • Patent number: 8813824
    Abstract: Certain exemplary embodiments can provide a system, machine, device, manufacture, circuit, and/or composition of matter adapted for and/or resulting from, and/or a method for activities that can comprise and/or relate to, a first form comprising: a plurality of surface artifacts that substantially spatially replicate a surface geometry of a stacked foil mold; and a prong that is adapted to form a hole in a cast product.
    Type: Grant
    Filed: December 5, 2012
    Date of Patent: August 26, 2014
    Assignee: Mikro Systems, Inc.
    Inventors: Michael Appleby, John Paulus, Iain Fraser, Jill Klinger, Benjamin Heneveld
  • Patent number: 8813820
    Abstract: A gravity casting mold including a first mold, a second mold and an exhaust runner mold, which are combined with each other and form a turbine housing cavity having a twin scroll part, a first riser, a sprue, a runner, a second riser, an exhaust manifold cavity, third risers and gates. A heating sleeve is provided in the first riser so as to prevent shrinkage of the molten metal in the twin scroll part. The heating sleeve is closed in an upper end, with a gas ejection hole formed through the upper end of the heating sleeve. A sprue cup is provided in the sprue so as to maintain the temperature of the molten metal in the sprue. The gravity casting mold further includes a twin scroll mold, a main gate core, an exhaust runner core, a twin scroll part core and a bypass part core, and a sub-gate core.
    Type: Grant
    Filed: January 8, 2014
    Date of Patent: August 26, 2014
    Assignee: SEYUN SCS Corporation
    Inventors: Sehoon Chang, Ildo Jung
  • Patent number: 8813812
    Abstract: A hollow turbine engine component with complex internal features can include a first region and a second, high resolution region. The first region can be defined by a first ceramic core piece formed by any conventional process, such as by injection molding or transfer molding. The second region can be defined by a second ceramic core piece formed separately by a method effective to produce high resolution features, such as tomo lithographic molding. The first core piece and the second core piece can be joined by interlocking engagement that once subjected to an intermediate thermal heat treatment process thermally deform to form a three dimensional interlocking joint between the first and second core pieces by allowing thermal creep to irreversibly interlock the first and second core pieces together such that the joint becomes physically locked together providing joint stability through thermal processing.
    Type: Grant
    Filed: August 23, 2013
    Date of Patent: August 26, 2014
    Assignees: Siemens Energy, Inc., Mikro Systems, Inc.
    Inventors: Ahmed Kamel, Gary B. Merrill
  • Publication number: 20140202650
    Abstract: A composite core for forming a passage in an investment casting mold is provided including a generally hollow structural element. The structural element is configured to deform when a force is applied to an end thereof. A rigid shell element is formed about the structural element. The shell element extends beyond both an interior surface and an exterior surface of the structural element. The shell element is configured to shatter when the structural element deforms.
    Type: Application
    Filed: January 23, 2013
    Publication date: July 24, 2014
    Applicant: SIKORSKY AIRCRAFT CORPORATION
    Inventors: Shihong G. Song, James S. Giampapa, John H. Meeson, JR.
  • Publication number: 20140182809
    Abstract: An investment casting core includes a mullite-containing core body. The body can be made by providing a mullite-containing powder, forming the powder into a green body, and sintering the green body to form the mullite-containing core body.
    Type: Application
    Filed: December 28, 2012
    Publication date: July 3, 2014
    Applicant: UNITED TECHNOLOGIES CORPORATION
    Inventor: Mario P. Bochiechio
  • Patent number: 8695683
    Abstract: An airfoil for a turbine engine includes a structure having a cooling passage that has a generally radially extending cooling passageway arranged interiorly relative to an exterior surface of the structure. The cooling passageway includes multiple cooling slots extending there from toward the exterior surface and interconnected by a radially extending trench. The trench breaks the exterior surface, and the exterior surface provides the lateral walls of the trench. The airfoil is manufactured by providing a core having multiple generally axially extending tabs and a generally radially extending ligament interconnecting the tabs. The structure is formed about the core to provide the airfoil with its exterior surface. The ligament breaks the exterior surface to form the radially extending trench in the exterior surface of the structure.
    Type: Grant
    Filed: June 14, 2011
    Date of Patent: April 15, 2014
    Assignee: United Technologies Corporation
    Inventors: Jason Edward Albert, Atul Kohli, Eric L. Couch
  • Patent number: 8689854
    Abstract: A method of fabricating a decomposition conduit with an in-line static mixer, the method including molding a decomposition conduit housing around a sand core by inserting molding material into a cavity between a decomposition conduit housing mold and the sand core, where the sand core includes a static mixer and, where the act of molding the decomposition conduit housing is operative to mount the static mixer to the molded decomposition conduit housing.
    Type: Grant
    Filed: February 22, 2011
    Date of Patent: April 8, 2014
    Assignee: Deere & Company
    Inventor: David S. Young
  • Publication number: 20140034263
    Abstract: An apparatus and method for molding a freight car yoke with a one piece core is disclosed herein. An exemplary one piece core may be used with a core mold upper half and a core mold lower half mated at a common split line to define a mold cavity which replicates the molded exterior features of a freight car yoke. The one piece core may replicate all of the molded internal features of a freight car yoke. An apparatus may use a pair of one piece cores to produce a pair of freight car yokes. An exemplary method can utilize the apparatus to produce a pair of freight car yokes through a single pour, using a pair of one piece cores. In an exemplary embodiment the one piece cores are constructed from a cold box with phenolic urethane treated molding sand.
    Type: Application
    Filed: October 1, 2013
    Publication date: February 6, 2014
    Applicant: Columbus Steel Castings Company
    Inventors: Steven R. Pinkstock, Craig A. Holman, Ronald A. Poe
  • Patent number: 8627875
    Abstract: This invention teaches an improved apparatus and method to make metal alloy castings, such as freight car yokes. One embodiment of the invention comprises a core mold assembly unit, wherein the mold unit is filled with molten metal. The core mold assembly units may be further formed of the same material, such as phenolic urethane impregnated sand, which is used to accurately replicate the desired shape of a final desired product.
    Type: Grant
    Filed: July 16, 2009
    Date of Patent: January 14, 2014
    Assignee: Columbus Steel Castings Company
    Inventors: Steven R. Pinkstock, Craig A. Holman, Ronald A. Poe
  • Patent number: 8627877
    Abstract: A core or foundry sand that can be used for the production of cores and casting molds for the casting of molten metals includes a basic molding material, a layer of an adhesive agent coating the basic molding material, and a layer of water glass lying over the adhesive agent layer. The core or foundry sand has a water content in the range of ? approximately 0.25% by weight to approximately 0.9% by weight in relation to the overall weight of the core or foundry sand.
    Type: Grant
    Filed: August 25, 2009
    Date of Patent: January 14, 2014
    Assignee: Minelco GmbH
    Inventor: Ralf-Joachim Gerlach
  • Patent number: 8615875
    Abstract: A method of manufacturing a metal blading sector for low-pressure guide vanes of a turbomachine of which at least one blade includes an internal cavity configured to accept or communicate with a gas detection probe and at least one hole formed in the wall constituting a passage for gas from a low-pressure zone of the turbomachine toward the cavity and the probe through the fitting, into a casting mold, of a core corresponding to the cavity and the casting of a molten metal in the cavity of the casting mold. The core includes, for each hole for communication with the cavity, a protrusion penetrating the internal surface of the mold and constituting the only element holding the core in position in the casting mold.
    Type: Grant
    Filed: July 16, 2009
    Date of Patent: December 31, 2013
    Assignee: Snecma
    Inventors: Damien Alquier, Sebastien Digard Brou De Cuissart
  • Publication number: 20130292083
    Abstract: A polyisocyanate component for a moulding material binding agent system is described containing at feast one sulfonic acid in a solution of at least one polyisocyanate, containing at least two NCO-groups in the molecule.
    Type: Application
    Filed: November 21, 2011
    Publication date: November 7, 2013
    Applicant: Huttenes-Albertus Chemische Werke GMBH
    Inventors: Gérard P.M. Ladégourdie, Markus Dörschel, Amine Serghini Anbari, Ursula Wichmann
  • Patent number: 8574476
    Abstract: A melt is made by heating a salt mixture containing a salt of sodium. The melt is set at a temperature higher than the liquidus temperature of the salt mixture, and poured into a mold for expendable core molding. The temperature when the melt is completely poured into the mold is set within a range not exceeding the liquidus temperature of the salt mixture by 30° C. An expendable salt core for casting is molded by solidifying the melt inside the mold. This makes it possible to more stably obtain the strength of a water-soluble expendable salt core for casting made of a salt cast product obtained by melting and molding salts of sodium and the like.
    Type: Grant
    Filed: May 11, 2009
    Date of Patent: November 5, 2013
    Assignee: Buhler AG
    Inventor: Youji Yamada
  • Patent number: 8555950
    Abstract: Heat flow and mechanical strength of an engine component are improved by an organic-like casting core. Hardened granules are formed of a core material having a three-dimensional solid shape. A secondary binder is applied to the hardened granules. A multiplicity of the granules are agglomerated in a master mold in a shape of a water jacket of the engine component, and the secondary binder is hardened to form an organic-like core having a continuous web structure. A plurality of other cores are formed in respective master molds to define respective surfaces of the engine component. The organic-like core is assembled with the other cores to form a casting mold. The engine component is cast by flowing molten metal into the casting mold, thereby forming a continuous parent metal bridging the water jacket having a predetermined porosity. The core material is removed from the engine component after casting.
    Type: Grant
    Filed: October 25, 2011
    Date of Patent: October 15, 2013
    Assignee: Ford Global Technologies, LLC
    Inventor: Charles Fabros
  • Publication number: 20130264022
    Abstract: The invention relates to a method for producing a cylinder (10, 110) for a two-stroke engine, comprising the following steps: producing a casting core (30, 130), wherein a central core slide (31, 131) for the cylinder chamber (11, 111) and at least one salt core (33, 133) for an overflow channel (18, 19; 118, 119) are produced and the at least one salt core (33, 133) is connected to the central core slide (31, 131), inserting the casting core (30, 130) into a casting mold, casting the cylinder (10, 110) in a die-casting process, removing the central core slide (31, 131) from the cylinder (10, 110), wherein the at least one salt core (33, 133) is separated from the central core slide (31, 131), and flushing the at least one salt core (33, 133) out of the cylinder (10, 110). The invention further relates to a casting core (30, 130) for such a method.
    Type: Application
    Filed: July 5, 2011
    Publication date: October 10, 2013
    Applicant: MAHLE INTERNATIONAL GMBH
    Inventors: Guenther Mayer, Juergen Schwarz, Torsten Eil
  • Patent number: 8540009
    Abstract: An exemplary method for forming a sand core includes forming a core insert; forming a sand core precursor around the core insert; and creating at least one passage within the sand core precursor by removing or otherwise transforming a portion of the core insert, wherein the at least one passage includes at least one exit point. The sand core may then be utilized in a casting mold assembly to form a cast part.
    Type: Grant
    Filed: February 23, 2009
    Date of Patent: September 24, 2013
    Assignee: GM Global Technology Operations LLC
    Inventors: Michael J. Walker, Thomas C. Pederson, Jason R. Traub, Anil K. Sachdev
  • Publication number: 20130220571
    Abstract: A multi-wall ceramic core for casting an airfoil with one or more internal cooling passages is made by preforming at least one fugitive core insert to have a joint-forming surface with a male and/or female joint feature and then forming at least one fugitive core insert in-situ adjacent and integrally connected and fused to the at least one preformed core insert at the joint-forming surface to form an interlocked, fused joint to form a composite core insert that includes features to form internal passage surfaces in the core when the composite core insert is removed. Another aspect involves preforming first and second fugitive core inserts to have respective joint-forming surfaces with respective snap-fittable joint features and assembling the first and second fugitive core inserts to form a composite core insert by snap fitting the snap-fittable joint features together to form an interlocked joint.
    Type: Application
    Filed: March 13, 2013
    Publication date: August 29, 2013
    Applicant: Howment Corporation
    Inventors: Boyd A. Mueller, Darren K. Rogers, Timothy J. Molamphy