Abstract: A turbine engine airfoil includes an airfoil structure having an exterior surface providing a leading edge. A radially extending first cooling passage is arranged near the leading edge and includes first and second portions. The first portion extends to the exterior surface and forms a radially extending trench in the leading edge. The second portion is in fluid communication with a second cooling passage. In one example, the second cooling passage extends radially, and the first cooling passage wraps around a portion of the second cooling passage from a pressure side to a suction side between the second cooling passage and the exterior surface. In the example, the first portion is arranged between the pressure and suction sides. In one example, the first cooling passage is formed by arranging a core in an airfoil mold. The trench is formed by the core in one example.

Abstract: A hybrid core assembly for a casting process includes a ceramic core portion, a first refractory metal core portion and a first plate positioned between the ceramic core portion and the first refractory metal core portion. The ceramic core portion includes a first trough. A portion of the refractory metal core portion is received in the first trough.

Abstract: In the sand core 10, the tar reducing agent is included in at least the second coating layer 13, which is the outermost layer, of the coating layers 12 and 13. Thus, the tar, which may be generated from the core body 11 and the coating layers 12 and 13 which are positioned thereinside, can be decomposed into low molecular gases (carbon monoxide, carbon dioxide, water, and the like) by heat of the molten metal. As a result, generation of the tar from the sand core 10 to the outside can be prevented. In this case, since the layer which includes the tar reducing agent is the second coating layer 13 which directly contacts the molten metal, the second coating layer 13 can directly receive the heat of the molten metal, and the tar generation prevention effects can be thereby remarkably obtained. Therefore, generation of defects in cast products which may be caused by clogging in the gas drain can be prevented, and structures of the gas drain of the die and the surroundings thereof can be simplified.

Abstract: A hybrid core assembly for a casting process includes a ceramic core portion and a refractory metal core portion that interfaces with a ceramic core trough of the ceramic core portion. The refractory metal core portion includes a finger having a bent portion that establishes a refractory metal core trough aligned with the ceramic core trough.

Abstract: A process for casting a turbine engine component is provided. The process comprises the steps of placing a refractory metal core assembly comprising two intersecting plates in a die, encapsulating the refractory metal 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 mold and method for gravity casting may integrally cast a turbine housing having a twin scroll unit and a bypass unit and an exhaust manifold having a plurality of exhaust runner units. A turbine housing-side riser may be formed based on the end portion of the twin scroll unit within a first mold and a second mold in the state where the cavity of the turbine housing is formed so that the end portion of the twin scroll unit which is the outlet of the turbine housing is upward disposed.

Abstract: A hybrid ceramic/sand casting method of manufacturing a metal part. The method is especially suitable for parts having one or more very small internal gaps, such as might occur with a linear passage or round opening. 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 gap. 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 gap.

Abstract: A ceramic core used for cast an air cooled turbine rotor blade or stator vane for a gas turbine engine, the ceramic core includes a larger ceramic core piece connected to a smaller ceramic core piece with a number of even smaller cross-over hole forming pieces connecting the larger piece to the smaller piece, and a strain relief slot formed in the larger ceramic core piece adjacent to the cross-over hole forming pieces that prevent the smaller cross-over hole pieces from breaking during the casting process from relative movement of the larger ceramic core piece with respect to the smaller ceramic core piece. The strain relief slot can be used to cast a rotor blade or a stator vane.

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 casting core assembly includes a metallic core and a ceramic core. The process for forming the casting core assembly includes inserting a ceramic plug of a metallic core and ceramic plug core subassembly into a compartment of the ceramic core. The ceramic plug is secured to the ceramic core.

Abstract: A turbine component has an airfoil portion with at least one central core element, a pressure side wall, and a suction side wall. The airfoil portion also has a serpentine cooling passageway in at least one of the walls. In a preferred embodiment, the airfoil portion has a serpentine cooling passageway in both of the pressure and suction side walls. A refractory metal core for forming the serpentine cooling passageway(s) is also described.

Abstract: A turbine component has an airfoil portion with at least one central core element, a pressure side wall, and a suction side wall. The airfoil portion also has a serpentine cooling passageway in at least one of the walls. In a preferred embodiment, the airfoil portion has a serpentine cooling passageway in both of the pressure and suction side walls. A refractory metal core for forming the serpentine cooling passageway(s) is also described.

Abstract: A method of making a casting is disclosed. At least one support member has at least one first portion and a plurality of second portions connected to a mold core. The mold core is positioned at least in part in a sealed interior volume of a negative mold. The first portion is positioned outside the interior volume. The second portions are positioned at least in part inside the interior volume. A consumable pattern material is introduced into the negative mold to create a consumable pattern. The support member is disposed at least in part outside the consumable pattern. The consumable pattern is removed from the negative mold. A shell is formed around the consumable pattern. A casting material is introduced into an interior of the shell to create a final casting. The support member is disposed at least in part outside the final casting. A mold core is also described.

Abstract: A core-in-a-core casting method and hybrid core (40) for use in the method. An inner core (42) formed of process-inert particles disposed in a binder material is used as a mold for casting an outer core ((44) formed of particles that will sinter during a subsequent firing step. The inner core provides mechanical support for the outer core during the firing step, and during which the inner core devolves into compacted but unbonded particles that can be removed conveniently from the outer core following the firing step to reveal the fired hollow outer core (44).

Abstract: A core-in-a-core casting method and hybrid core (40) for use in the method. An inner core (42) formed of process-inert particles disposed in a binder material is used as a mold for casting an outer core ((44) formed of particles that will sinter during a subsequent firing step. The inner core provides mechanical support for the outer core during the firing step, and during which the inner core devolves into compacted but unbonded particles that can be removed conveniently from the outer core following the firing step to reveal the fired hollow outer core (44).

Abstract: The pattern has a pattern material and a casting core combination. The pattern material has an airfoil. The casting core combination is at least partially embedded in the pattern material. The casting core combination comprises a metallic casting core and at least one additional casting core. The metallic casting core has opposite first and second faces. The metallic core and at least one additional casting core extend spanwise into the airfoil of the pattern material. In at least a portion of the pattern material outside the airfoil of the pattern material, the metallic casting core is bent transverse to the spanwise direction so as to at least partially surround an adjacent portion of the at least one additional casting core.

Abstract: A one-piece core-making technique used in producing railway truck bolsters and side frames, which includes the following steps: 1. After scraping the top of a core box, applying a shaped top mould (11), which is precisely located, from top to bottom. 2. Press or slightly hit the top mould (11) to make sure the top mould covers/caps the scraping surface. 3. Keep pressing to make sure that the flat scraping surface was pressed to a required curved shape, like the shape of the top mould (11). 4. Last, it will become a one-piece core with a partially integrated inner cavity section. The one-piece core made by this technique has a smooth surface. This technique also can improve the internal quality of the product and ease work intensity.

Abstract: The invention relates to a soluble and essentially annular casting core (2) for forming a cooling channel that transitions into two areas (14, 15) which are approximately parallel to the piston axis (16) and are facing away from the piston head (3), via a respective bending of the core (17, 18) in the shape of a quadrant, wherein the second area (14) transitions into a part of the casting core (2) that forms the feed opening (12) of the cooling channel, and the first area (15) transitions into a part of the casting core (2) that forms the discharge opening (13) of the cooling channel. The two areas (14, 15) of the casting core (2) are disposed at a distance from one another, which corresponds at a maximum to two times the cross-sectional diameter of one of the two areas (14, 15). As a result, the throughflow of the cooling oil traversing the cooling channel is accelerated and the cooling of the piston improved.

Abstract: Additives to foundry sand cores are provided for reducing or eliminating surface defects in metal castings. The additives general comprise an iron oxide component and a glass component which is preferably free of lithium oxide.

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. A mating edge portion of the metallic casting core includes a number of projections. The first region is along at least some of the projections. A number of recesses span gaps between adjacent projections. The ceramic feedcore includes a number of compartments respectively receiving the metallic casting core projections. The ceramic feedcore further includes a number of portions between the compartments and respectively received in the metallic casting core recesses.

Abstract: A molding technique is utilized to form the cooling channels in an airfoil for a gas turbine engine. The cooling channels are formed by lost core mold cores, which are leached away after metal has been molded around them. At least one of the mold cores is provided with a cone which will extend into the airfoil. The cone forms an opening in a wall of the airfoil, and the size of this opening is indicative of the thickness of the wall. By comparing the size to expected sizes, a determination can be made of whether the wall is of an acceptable thickness at locations where it is difficult to otherwise measure the wall.

Abstract: A soluble casting core for forming a cooling channel in a piston has a formed-on part for forming an oil supply opening and a formed-on part for forming an oil drain opening. In order to improve the mechanical strength of the piston, the oil supply opening and the oil drain opening lie in a different pin boss support of the pin bosses of the piston. A third formed-on part, which lies in the circumferential direction and is configured in oblong manner, is disposed between the first formed-on part and the end of the casting core, which part has a shape that narrows conically towards the end of the casting core and forms a continuation of the cooling channel, which narrows conically towards the end of the cooling channel.

Abstract: A casting includes a wall thickness check feature for measuring thickness of a wall second aside an in-wall cooling passageway. The thickness is determined by observing the existence and/or size of an opening formed by the feature. The casting is cast from a pattern including portions forming the feature. To manufacture the pattern, a pattern-forming die is assembled with a ceramic feedcore and a refractory metal core (RMC). The assembling leaves an inlet portion of the RMC engaged to the ceramic feedcore and leaves an outlet portion of the RMC engaged to the die. A pattern-forming material is molded in the die at least partially over the ceramic feedcore and RMC. The die is disengaged from the pattern-forming material. The assembling engages a stepped projection of the RMC with a mating surface of the die.

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: The present invention relates to a core or foundry sand that can be used for the production of cores and casting moulds for the casting of molten metals, comprising a basic moulding material, coated with a layer of an adhesive agent and a layer of water glass lying over the latter and a water glass 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 and foundry sand.

Abstract: A substrate is coated by applying an essentially pure aluminum first layer to a surface of the substrate. At least a first portion of the first layer is oxidized so as to provide a protective coating of desired properties. The substrate may be a refractory metal-based investment casting core.

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 rare earth-based core for use in the casting of a reactive metal is described. The core contains a ceramic composition which includes at least about 10% by weight of monoclinic rare earth aluminate (RE4Al2O9), wherein RE represents at least one rare earth element; and at least about 10% by weight of at least one free rare earth oxide. The ceramic phase of the composition may include a microstructure which comprises a multitude of substantially spherical pores which are formed as a result of the removal of aluminum metal from the core composition during a heat treatment step. Additional embodiments relate to a method for the fabrication of a ceramic core, employing a rare earth oxide, aluminum metal, and a binder. Methods for removing cores from a cast part are also described.

Abstract: A cast metal article, such as a turbine engine component, is made by shaping a body of refractory metal particles to form a molded refractory metal article. The molded refractory metal article is sintered to form a refractory metal core. Both the refractory metal article and a setter block may be sintered at the same time. At least a portion of the refractory metal core is enclosed with wax. The wax is at least partially enclosed with a covering of mold material. The wax is removed from the mold material to form an article mold cavity. The article mold cavity is filled with molten metal which solidifies to form a cast metal article. The refractory metal core is removed from the cast metal article.

Abstract: A binder material for binding a plurality of particles together to form a conglomerate such as a carbon-containing briquette, a sand casting core and the like is provided. The binder material can include a collagen and/or lignin and a plurality of inorganic particles. In some instances, the binder material can be used to make a composite material. The composite material can include a plurality of particles and the binder material that contains the collagen and/or lignin. The binder material affords for the plurality of particles to be bound together into a desired shape, the desired shape having desirable properties.

Abstract: Additives to foundry sand cores are provided for reducing or eliminating surface defects called veins in metal castings, by reducing the propensity of sand mold and core aggregates to crack during metal casting. The additives generally include an iron oxide component such as magnetite and hematite and a glass component which is preferably free of lithium oxide. The additive may also optionally include an amount of carbon effective to reduce adhesion of sand particles to the casting.

Abstract: Disclosed herein is an integral casting core including a solidified first portion of a ceramic core and a solidified second portion of the ceramic core; wherein the solidified second portion is disposed upon the solidified first portion of the ceramic core by laser consolidation. The first solidified portion of the integral casting core, is manufactured by a process which includes disposing a slurry including ceramic particles into a metal core die; wherein an internal volume of the metal core die has a geometry equivalent to a portion of the geometry of the integral casting core; curing the slurry to form a cured first portion of the ceramic core; and firing the cured first portion of the ceramic core to form a solidified first portion of the ceramic core.

Abstract: In the sand core 10, the tar reducing agent is included in at least the second coating layer 13, which is the outermost layer, of the coating layers 12 and 13. Thus, the tar, which may be generated from the core body 11 and the coating layers 12 and 13 which are positioned thereinside, can be decomposed into low molecular gases (carbon monoxide, carbon dioxide, water, and the like) by heat of the molten metal. As a result, generation of the tar from the sand core 10 to the outside can be prevented. In this case, since the layer which includes the tar reducing agent is the second coating layer 13 which directly contacts the molten metal, the second coating layer 13 can directly receive the heat of the molten metal, and the tar generation prevention effects can be thereby remarkably obtained. Therefore, generation of defects in cast products which may be caused by clogging in the gas drain can be prevented, and structures of the gas drain of the die and the surroundings thereof can be simplified.

Abstract: An unfired ceramic base core having a first coefficient of thermal expansion is provided. A core element having a second coefficient of thermal expansion is positioned in an opening formed in the unfired ceramic base core. The opening in the unfired ceramic base core is filled with a filler material having a third coefficient of thermal expansion. The third coefficient of thermal expansion is greater than the first coefficient of thermal expansion and less than the second coefficient of thermal expansion. The ceramic base core is fired without cracking the base core and without cracking the filler material. The ceramic base core contains silica and zircon and has a silica content of 70% or less and a zircon content of 30% or more. The core element may be formed of a ceramic material or a refractory metal.

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: An article includes a blade casting core combination. The combination includes a ceramic feedcore and a metallic core. The ceramic feedcore has: a root end; a tip end; a leading end; a trailing end; a first side; a second side; and a plurality of legs extending between the root and tip ends and arrayed between the leading and trailing ends. The metallic core has: a first face; a second face; a first portion extending from the feedcore trailing end; and a second portion extending from the tip end. The article may be a pattern where the core is embedded in a wax or may be a shell formed from such a pattern. The article may be used in a method for forming the resultant blade.

Abstract: The invention pertains to methods for manufacturing objects in moulds, the moulds used for the manufacture and objects manufactured in accordance with the method and/or in the moulds.

Abstract: The present invention provides a structure for producing cast articles containing one or more inorganic particles selected from amorphous and artificial graphites, an inorganic fiber and a thermosetting resin and having a gas permeability of 1 to 500.

Abstract: Compositions suitable for use as cores and shell molds for casting of reactive metal alloys, and casting processes for producing components from such alloys. The composition contains a sintered particulate material of hafnia and at least one additional metal oxide in amounts to yield a ceramic composition containing up to 70 molar percent of hafnia, wherein the additional metal oxide is a rare-earth oxide, the sintered particulate material contains first and second phases, the first phase is the rare-earth oxide and hafnia in solid solution, the second phase is a compound of the rare-earth oxide and hafnia, and the second phase is less reactive with the reactive metal alloy than the first phase.

Abstract: A core for investment casting processes includes a core having one or more ceramic materials; and an exterior layer of metal material not susceptible to oxidation under investment casting operating conditions. A method for casting a turbine engine component having an internal passageway includes the steps of forming one or more mold sections each having internal surfaces and at least one of the aforementioned cores for forming one or more turbine engine components having at least one internal passageway; assembling the one or more mold sections; introducing a molten alloy into the one or more assembled mold sections; and consuming the metal of the at least one core during the process.

Abstract: A turbine blade airfoil assembly includes a cooling air passage. The cooling air passage includes a plurality of impingement openings that are isolated from at least one adjacent impingement opening. The cooling air passage is formed and cast within a turbine blade assembly through the use of a single core. The single core forms the features required to fabricate the various separate and isolated impingement openings. The isolation and combination of impingement openings provide for the augmentation of convection and film cooling and provide the flexibility to tailor airflow on an airfoil to optimize thermal performance of an airfoil.

Abstract: A core for investment casting processes includes a core having one or more ceramic materials; and an exterior layer of metal material not susceptible to oxidation under investment casting operating conditions. A method for casting a turbine engine component having an internal passageway includes the steps of forming one or more mold sections each having internal surfaces and at least one of the aforementioned cores for forming one or more turbine engine components having at least one internal passageway; assembling the one or more mold sections; introducing a molten alloy into the one or more assembled mold sections; and consuming the metal of the at least one core during the process.

Abstract: A rare earth-based core for use in the casting of a reactive metal is described. The core contains a ceramic composition which includes at least about 10% by weight of monoclinic rare earth aluminate (RE4Al2O9), wherein RE represents at least one rare earth element; and at least about 10% by weight of at least one free rare earth oxide. The ceramic phase of the composition may include a microstructure which comprises a multitude of substantially spherical pores which are formed as a result of the removal of aluminum metal from the core composition during a heat treatment step. Additional embodiments relate to a method for the fabrication of a ceramic core, employing a rare earth oxide, aluminum metal, and a binder. Methods for removing cores from a cast part are also described.

Abstract: An upper surface of a skirting base section 6h of a sand core 6 is provided with a projection 14 of a column shape. When a slide mold 3 is slidingly moved in a mold clamping direction, a sliding contact section 15 of a holding recessed section 13 of the slide mold 3 is brought into sliding contact with the projection 14 to hold the projection 14 while scraping away part of the sand of the projection 14. The upper surface of the skirting base section 6h adjacent to the projection 14 is also provided with a recess 16 for recovering the scraped sand, wherein the width of the recess 16 is larger than the diameter of the projection 14 in the longitudinal direction. The projection 14 can be formed in a prismatic or semispherical shape.

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.

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: A ceramic core used to make a first or second stage turbine blade in an industrial gas turbine engine. The ceramic core includes a serpentine flow forming pierce with a trailing edge cooling supply channel forming piece on the trailing edge end. Three rows of metering holes are formed by a core piece in which a continuous flow channel piece on the tip portion and the root portion of the blade support the core piece that forms the metering holes and impingement cavity pieces such that the ceramic core is rigid and strong to prevent shear force and local bending of the core during casting will not break the core. A first and a second stage turbine blade is formed from the ceramic core and includes a forward flowing serpentine flow circuit for the first stage blade with the first channel of the serpentine flow circuit forming the trailing edge supply channel. A second stage blade includes an aft flowing serpentine flow circuit with the last channel forming the trailing edge supply channel.

Abstract: A method involves forming a core assembly. The forming includes molding a first ceramic core over a first refractory metal core to form a core subassembly. The subassembly is assembled to a second ceramic core.

Abstract: A method of casting a rotary friction plate includes preparing a casting mold with a cavity and a core shaped to form the friction plate. Molten metal is poured into the mold through a central sprue where a portion of the metal flows radially outward across the top of the core to fill friction plate forming regions of the cavity from above, while another portion flows through a central opening in the core to fill a hub forming region at the bottom of the cavity as well as additionally supply metal to the lower friction plate forming region from below. The metal is allowed to cool, which begins at the radially outer regions of the at least one friction surface and progresses radially inward to develop a uniform cast structure.

Abstract: The invention relates to a soluble and essentially annular casting core (2) for forming a cooling channel that transitions into two areas (14, 15) which are approximately parallel to the piston axis (16) and are facing away from the piston head (3), via a respective bending of the core (17, 18) in the shape of a quadrant, wherein the second area (14) transitions into a part of the casting core (2) that forms the feed opening (12) of the cooling channel, and the first area (15) transitions into a part of the casting core (2) that forms the discharge opening (13) of the cooling channel. The two areas (14, 15) of the casting core (2) are disposed at a distance from one another, which corresponds at a maximum to two times the cross-sectional diameter of one of the two areas (14, 15). As a result, the throughflow of the cooling oil traversing the cooling channel is accelerated and the cooling of the piston improved.