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: 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: 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 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.

Abstract: A method of manufacturing a cylinder block using a die apparatus wherein a columnar hole includes a bore in the cylinder block. The method includes the steps of abutting first and second split cores against an upper surface of a distal end core, the upper surface being located opposite the inner core, and introducing a molten metal into a cavity. An inner core is withdrawn to move the first and second split cores toward an axis. The first and second split cores are released from a formed product made of solidified molten metal. The split cores are removed from the formed product to form the bore, and an inner surface of the bore is cut.

Abstract: A mold and a die-cast manufacturing method for the die-cast product, in which a main frame which is contiguously formed with a head pipe constitutes a portion of a hollow light-weight-metal-made vehicle-body frame. The mold includes a core for forming an inner space of the hollow vehicle-body frame. The core includes a core body and a plurality of splints mounted on the core body, the splints having approximately elliptical cross-sectional shapes. The long axes direction of ellipses of the splints are set parallel to a mold split surface of the mold. As a result, measurement of the positional accuracy of the splints is facilitated, a clearance between the splint and the mold can decrease by increasing the dimensional accuracy of splint mounting portions of the mold based on sizes of the splints, and the frame can be manufactured with high dimensional accuracy.

Abstract: Diecasting tool for the production of a cylinder crankcase (2), comprising a salt core (4) and at least one cylinder sleeve (6), wherein the cylinder sleeve (6) comprises an upper end (8) on the cylinder head side, and a lower end (10) on the crankshaft side, and the cylinder sleeve (6) is supported on at least one center sleeve that is disposed on the diecasting tool, and the salt core (4) at least partially surrounds the cylinder sleeve (6) in the manner of a cladding, wherein the salt core (4) comprises a crown (12) that at least partially bears on one of the ends (8, 10) of the cylinder sleeve (6), and the core (4) comprising openings (14) that extend vertically beneath the end (8) of the cylinder sleeve (6) on the cylinder head side.

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 blade outer air seal (BOAS) casting core has first and second end portions and a plurality of legs. Of these legs, first legs each have: a proximal end joining the first end portion; a main body portion; and a free distal portion. Second legs each have: a proximal end joining the second end portion; a main body portion; and a free distal portion.

Abstract: In a method for manufacturing a combination investment casting core, a plurality of cores are each formed by cutting a metallic sheet to define a first portion and a number of separate second portions linked by the first portion. The second portions are bent out of local alignment with the first portion. The first portions of the cores are assembled and secured to each other.

Abstract: To manufacture a casting core, one or more recesses are formed in at least one face of metallic sheetstock. After the forming, a piece is cut from the metallic sheetstock. The piece is deformed to a non-flat configuration.

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 blade outer air seal (BOAS) casting core has first and second end portions and a plurality of legs. Of these legs, first legs each have: a first end joining the first end portion; a main body portion; and a second end. Second legs each have: a second end joining the second end portion; a main body portion; and a first portion. At least one of the second legs may have its first end joining the core first end portion and a plurality of apertures in the main body portion. Alternatively, at least one of the first legs may have its second end joining the core second end portion and a plurality of apertures in its main body portion.

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

Abstract: A method of forming an integral casting core includes adding a disposable insert to a metal core die and disposing a slurry into the metal core die. The slurry includes ceramic particles. The method further includes firing the slurry to form a integral casting core and removing the disposable insert from the integral casting core.

Abstract: A core assembly including two cores is used to manufacture a blade. The first core has an outer surface shaped to complement the tip wall bottom surface. The second core has a tip surface, a side surface, and a protrusion or a depression. The tip surface is shaped to complement at least a portion of the tip wall top surface and is configured to be disposed proximate the first core. The side surface is shaped to complement at least a portion of the side wall, and the protrusion extends from the second core side surface to contact at least a portion of the ceramic mold inner surface. In embodiments employing a depression, the depression is formed in the side surface.

Abstract: A method of fabricating a core for a ceramic shell mold is disclosed. A porous core body is formed from at least about 50% by weight of at least one rare earth metal oxide. The core body is heated under heating conditions sufficient to provide the core with a density of about 35% to about 80% of its theoretical density. The core body is then infiltrated with a liquid colloid or solution of at least one metal oxide compound, e.g., rare earth metal oxides; silica, aluminum oxide, transition metal oxides, and combinations thereof. The infiltrated core body is then heated to sinter the particles without substantially changing the dimensions of the core body. Mold-core assemblies which include such a core body are also described. A description of processes for casting a turbine component, using the core, is also set forth herein.

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 substrate is coated by applying a first layer atop the substrate and including, in major weight part, a non-refractory first metal. A second layer is applied atop the first layer and includes, in major weight part, a carbide and/or nitride of a second metal. A third layer is applied atop the second layer and comprises, in major weight part, a ceramic. The substrate may be a refractory metal-based investment casting core.

Abstract: A molding process which comprises mixing together a particulate aggregate, plural kinds of water-soluble binders, a crosslinking agent causing crosslinking reaction with the binders, a phenol resin, and water, agitating the obtained mixture to prepare a bubbled fluid aggregate mixture, filling the aggregate mixture into a molding cavity, and solidifying the aggregate mixture through the evaporation of water from the mixture to give a mold made from the mixture.

Abstract: A refractory metal core for use in a casting system has a coating for providing oxidation resistance during shell fire and protection against reaction/dissolution during casting. In a first embodiment, the coating includes at least one oxide and a silicon containing material. In a second embodiment, the coating includes an oxide selected from the group of calcia, magnesia, alumina, zirconia, chromia, yttria, silica, hafnia, and mixtures thereof. In a third embodiment, the coating includes a nitride selected from the group of silicon nitride, sialon, titanium nitride, and mixtures thereof. Other coating embodiments are described in the disclosure.

Abstract: The present invention relates to a ceramic core used in the manufacture, by lost wax casting, of a turbomachine blade with cooling cavities and a squealer, comprising at least one main core, wherein the main core (10) comprises an element (10B) shaped so as to constitute the squealer and an element (10SB) shaped so as to constitute at least one cavity beneath the squealer, the two elements leaving between them a space (13) shaped so as to constitute, at least in part, the bottom wall of the squealer. In particular, the elements (10B and 10SB) are joined together by ceramic rods (TG).

Abstract: A plugged assembly of cores includes a first core having a first end portion, and a second core having a second end portion. The first end portion of the first core is connected to the second end portion of the second core by a mortise and tenon type connection to form an assembly of the two cores having residual spaces formed by the mortise and tenon type connection, such residual spaces being liable to give rise to flashings when metal is poured over the assembly if not plugged. Residual spaces formed by the mortise and tenon type connection in the assembly of the two cores contain a material configured to reduce the possibility of flashings.

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: A process for manufacturing a ceramic foundry core having at least one thin region with a thickness “e”, in particular in of a turbomachine blade trailing edge, including the forming in a mold of a mixture including a ceramic particle filler and an organic binder, the extraction of the core from the mold, the binder removal and consolidation heat treatment of the core. The process is one in which a core is formed in the mold, the region of this core being thickened relative to the thickness “e” by an overthickness E and in which the overthickness is machined after the core has been extracted from the mold and before or after the heat treatment operation. In particular, the machining is carried out mechanically by milling, either with removal of chips on the cores before firing, or by abrasion on the fired cores.

Abstract: An investment casting pattern component has a spine and a number of tines extending from the spine.

Abstract: Disclosed herein is a method comprising injecting into a thin wall disposable core die a slurry having a viscosity of about 1 to about 1,000 Pascal-seconds at room temperature when tested at a shear rate of up to 70 seconds?1 and a flow index of less than 0.6 at a pressure of up to about 7 kilograms-force per square centimeter; wherein the thin wall disposable core die has an average wall thickness of about 1.5 to about 10 millimeters; curing the slurry to form a cured ceramic core; removing the thin wall disposable core die from the cured ceramic core; and firing the cured ceramic core to form a solidified ceramic core.

Abstract: A core for casting a metal part having a body with solid portions spaced apart by hollow portions. The body includes at least one support element extending between adjacent solid portions. The support element provides stiffness and strength for the casting core during the casting process. The support element has an optimized shape to prevent the core from fracturing during the casting process and to minimize operating stress in the metal part around the area formed by the support element.

Abstract: A core for use in casting a gas turbine bucket includes a solid, curved upper body portion and a pair of co-planar legs extending downwardly from the solid, curved upper body portions. The pair of legs are separated by an elongated open slot extending from a lower end of the core upwardly more than half a height dimension of the core, into the upper body portion. A pair of axially aligned pegs project in axially opposite directions from opposite sides of the solid, curved upper body portion, perpendicular to and above the elongated slot but spaced from an upper edge of the solid, curved upper body portion. The pair of pegs lie substantially in a plane containing the co-planar legs, and in a radial direction, the pegs are closer to the elongated slot than to the upper edge.

Abstract: A method of manufacturing a cast core with at least one recess, corresponding to a partition of a turbomachine blade, includes the steps of shaping, in a mold, a mixture containing a ceramic particles filler and an organic binder; forming a core rough casting without the recess in the mold; extracting the core rough casting from the mold; machining the recess in the core rough casting thereby forming a machined core with the recess; removing the organic binder from the machined core; and heat treating the machined core to consolidate the machined core. The step of machining the recess is performed before the step of heat treating the machined core.

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

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

Abstract: The present invention provides resin-coated sand containing spherical molding sand with a binder composition, the spherical molding sand having an average particle diameter of 0.02 to 1.5 mm and being produced by a flame fusion method.

Abstract: A core for casting a metal part having a body with solid portions spaced apart by hollow portions. The body includes at least one support element extending between adjacent solid portions. The support element provides stiffness and strength for the casting core during the casting process. The support element has an optimized shape to prevent the core from fracturing during the casting process and to minimize operating stress in the metal part around the area formed by the support element.

Abstract: Provided are methods of replacing drilling holes in castings by pre-tensioning sand cores. This methods are used in long cylindrical shaped sand cores in cold core box processes. The urethane sand core is placed in compression to increase the core strength during handling, placing inside of the mold. The pre-tensioned urethane sand core is set in a casting mold so as to form a cavity in the casting mold. The molten metal is poured to form the cavity inside of the casting. The pre-tensioned urethane sand core maintains its initial shape during casting.

Abstract: A cylinder block casting is disclosed having a bulkhead window formed therein, the bulkhead window is formed by a set core received in one of a chill assembly and an integral barrel crankcase core of a mold package.

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

Abstract: A turbine engine blade has an attachment root, a platform outboard of the attachment root, and an airfoil extending from the platform. The airfoil has pressure and suction sides extending between leading and trailing edges. An internal cooling passageway network includes at least one inlet in the root and a plurality of outlets along the airfoil. The passageway network includes a leading spanwise cavity fed by a first trunk. A streamwise cavity is inboard of a tip of the airfoil. A spanwise feed cavity feeds the streamwise cavity absent down-pass. A second trunk feeds the spanwise feed cavity.

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

Abstract: Disclosed herein is an article comprising a solidified first portion of a ceramic core; wherein the first solidified portion is manufactured by a process comprising disposing a slurry comprising 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; firing the cured first portion of the ceramic core to form a solidified first portion of the 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.

Abstract: An exemplary die-casting mold core includes a mold body, an intermediate layer and a diamond-like carbon film. The mold body is made of a steel alloy containing carbon, chromium, manganese, silicon, vanadium, and iron. A molar percentage of hydrogen in the diamond-like carbon film is in a range from 2% to 25%. The die-casting mold core has excellent mechanical hardness, good corrosion resistance, good wear resistance, long lifetime and ease of separation.

Abstract: A core assembly including two cores is used to manufacture a blade. The first core has an outer surface shaped to complement the tip wall bottom surface. The second core has a tip surface, a side surface, and a protrusion or a depression. The tip surface is shaped to complement at least a portion of the tip wall top surface and is configured to be disposed proximate the first core. The side surface is shaped to complement at least a portion of the side wall, and the protrusion extends from the second core side surface to contact at least a portion of the ceramic mold inner surface. In embodiments employing a depression, the depression is formed in the side surface.

Abstract: A method of fabricating a core for a ceramic shell mold is disclosed. A porous core body is formed from at least about 50% by weight of at least one rare earth metal oxide. The core body is heated under heating conditions sufficient to provide the core with a density of about 35% to about 80% of its theoretical density. The core body is then infiltrated with a liquid colloid or solution of at least one metal oxide compound, e.g., rare earth metal oxides; silica, aluminum oxide, transition metal oxides, and combinations thereof. The infiltrated core body is then heated to sinter the particles without substantially changing the dimensions of the core body. Mold-core assemblies which include such a core body are also described. A description of processes for casting a turbine component, using the core, is also set forth herein.

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

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

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