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 An inner core is withdrawn to move the first and second split cores toward an axis.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: 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: 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: 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: 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: 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 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 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 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: 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 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: 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: 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: 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: 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.

Abstract: The invention relates 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, comprising the forming in a mold of a mixture comprising 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 said mold, said region of this core being thickened relative to the thickness “e” by an overthickness E and in which said 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 engine block mold, including at least one barrel slab core (10), the or each barrel slab core (10) including a slab portion (12), and at least one barrel portion (14) adapted to receive a cylinder liner (1), wherein the barrel portion (14) of the or each barrel slab core (10) has an outer diametral taper along at least a portion of its length, and the or each liner (1) has a substantially matching internal diametral taper along at least a portion of its length. Inserting the or each slab barrel core (10) with the or each liner (1) disposed upon it, into a substantially completed mold casing, filling the mold, and then machining the cylinder liners (1) so that they have a substantially constant internal diameter along their length.

Abstract: Sacrificial lost casting cores of green or fired ceramic, which include at least one tension spring as a metallic reinforcing element, wherein at least one end of this reinforcing element lies near one of the surfaces of the casting core or extends therethrough, and wherein the melting point of all metallic reinforcing elements lie above the melting point of the casting metal, as well as processes for production of such casting cores, including the steps of preparing a principal mold, seating therein at least one reinforcing element, filling the principal mold with ceramic slip, drying the slip for formation of a green ceramic and releasing the casting core from the principal mold. The principal mold is preferably lined with a flexible internal mold or liner. The reinforcing element in the form a tension spring can be used following casting for breaking up the ceramic casting core.

Abstract: An internal metering structure permits the exit apertures of a cooled airfoil to be sized to provide for easy manufacturability.

Abstract: A composite core for an investment casting process, the core including both a ceramic portion and a refractory metal portion, with the refractory metal portion being so disposed as to perform the function of a plurality of such refractory metal elements. In particular, a refractory metal element attached to a trailing edge of a ceramic element extends beyond the plane of a tip end of the ceramic element so as to replace the refractory metal element otherwise extending from the ceramic tip edge. The refractory metal element also extends beyond the space to be occupied by the wax casting, both in the direction of the tip end and the trailing edge such that improved placement and securing of the core is facilitated during the casting process. A further embodiment uses a single refractory metal element that extends into both the airfoil portion and an orthogonal extending platform portion thereof.

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

Abstract: According to the prior art, through-holes in components are often introduced after the production (casting) of the component. This entails additional outlay in terms of time and equipment. The time required can be considerably shortened if a casting mold is designed in such a way that the through-hole is at least in part formed by corresponding projections being formed on the inner wall and/or the outer wall of the casting mold.

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.