Abstract: A mullite shell mold for casting includes a facecoat layer containing ceramic flour. The mullite shell mold also includes a first layer disposed on the facecoat layer. The first layer can contain sintered ceramic media. The facecoat layer and the first layer can each contain less than 1 wt % crystalline silica.

Abstract: An apparatus (1) for the additive manufacturing of at least one three-dimensional object (2) by selectively compacting layer by layer at least one compactible building material (3) by means of at least one energy beam (5) generated by at least one radiation generating device (4), comprising at least one radiation generating device (4) for generating at least one energy beam (5) for compacting at least one compactible building material (3), at least one coating device (8) for carrying out at least one coating operation to apply a defined building material layer (9) of at least one compactible building material (3) to a building plane (10) or to a building material layer (9) of at least one compactible building material (3) that has previously been applied in the course of carrying out a previous coating operation, and also at least one recording device (11) for recording layer information describing.

Abstract: A measurement device for measuring properties of a metal sheet processed in a rolling mill, including: an inspection coil set including a transmitter coil and a receiver coil, the transmitter coil being configured to apply a time-varying magnetic field to the metal sheet, and the receiver coil being configured to detect a magnetic field transient produced from the metal sheet. The property of the metal sheet is derivable from the magnetic field transient. A correction coil set, for detecting a spatial deviation of the metal sheet from a reference plane, each correction coil being connectable to a capacitor to form a respective resonance circuit having a resonance frequency. The correction coils are resonated at the respective resonance frequency. A shift in the resonance frequency in the presence of the metal sheet is detectable and the spatial deviation is derivable from the shifts.

Abstract: Vitriforming is a method for forming material into complex geometries within a vitreous substance. Liquid material is formed inside the vitreous substance through external forces applied to the vitreous forming medium. This technique can be broken down into four categories of operations: encasement, setup, forming, and extraction. All operations involve a forming medium, and a workpiece. The workpiece can be composed of any material so long as the forming medium is temperature, viscosity, and chemically compatible. The vitreous forming medium translates outside forces into the workpiece to create various geometries. This forming medium can remain a part of the final assembly or get extracted after forming takes place. Workpiece geometry is affected by forming tool geometry, initial setup, heat, and material properties. This process can be used as a fast, efficient means of forming metal or other materials with unique abilities to control material combinations, surface chemistry, texture, and overall geometry.

Abstract: A mold molding apparatus can successively mold casting molds having the necessary casting mold strength, and a method for controlling the mold molding apparatus. A molding sensor measures a pressure of molding sand exerted on a surface of one or both of a pattern plate and a squeeze foot, or on a surface of one or both of a pattern plate and a squeeze board; and a control device that controls operation of the mold molding apparatus based on outputs from the molding sensors.

Abstract: A mold molding apparatus can successively mold casting molds having the necessary casting mold strength, and a method for controlling the mold molding apparatus. A molding sensor measures a pressure of molding sand exerted on a surface of one or both of a pattern plate and a squeeze foot, or on a surface of one or both of a pattern plate and a squeeze board; and a control device that controls operation of the mold molding apparatus based on outputs from the molding sensors.

Abstract: A mold molding apparatus can successively mold casting molds having the necessary casting mold strength, and a method for controlling the mold molding apparatus. A molding sensor measures a pressure of molding sand exerted on a surface of one or both of a pattern plate and a squeeze foot, or on a surface of one or both of a pattern plate and a squeeze board; and a control device that controls operation of the mold molding apparatus based on outputs from the molding sensors.

Abstract: A mold molding apparatus can successively mold casting molds having the necessary casting mold strength, and a method for controlling the mold molding apparatus. A molding sensor measures a pressure of molding sand exerted on a surface of one or both of a pattern plate and a squeeze foot, or on a surface of one or both of a pattern plate and a squeeze board; and a control device that controls operation of the mold molding apparatus based on outputs from the molding sensors.

Abstract: A method of constructing a heat exchanger includes providing a base, and additively manufacturing a plurality of first walls substantially parallel and substantially vertical while being manufactured, wherein the plurality of first walls are spaced apart and attached to the base. The method also includes removing at least a portion of a build powder located between the plurality of first walls and attaching a parting sheet to the plurality of first walls. The method also includes additively manufacturing a plurality of second walls substantially parallel and substantially vertical while being manufactured and are spaced apart.

Abstract: A method for producing or assembling a product which includes at least two components, for example a motor vehicle or a motor vehicle module, by at least two fixing parts. The first fixing part is formed as a female part and the second fixing part is formed as a male part. The components disposed at a processing station and the first fixing part are measured by a measuring device, for example by a stationary camera or a camera fastened on a first or a second manipulator or photogrammetry bar having three cameras, and a deviation from a target geometry or target position is determined, and a corrected target position of the second fixing part is calculated on the basis of the determined deviation, such that the second fixing part is joined together with the first fixing part by the first manipulator and the product is thus produced.

Abstract: A method of additive manufacturing of an object includes directing laser energy from a laser to a region for material deposition, extruding material using an extruder at the region of material deposition, sensing temperature within the region of the material deposition, and electronically controlling the laser energy using the temperature so as to sufficiently heat the region for material deposition prior to extruding the material to increase strength of the object.

Abstract: A method of additive manufacturing of an object may include directing laser energy from a laser to a region for material deposition, extruding material using an extruder at the region of material deposition, sensing temperature within the region of the material deposition, and electronically controlling the laser energy using the temperature so as to sufficiently heat the region for material deposition prior to extruding the material to increase strength of the object. The method may include hardening or freezing extruded material through cooling in real-time.

Abstract: The present invention relates to a powder mixture for three-dimensional (3D) printing of a cermet or a cemented carbide body. The powder mixture includes 65-85 wt % of porous cemented carbide or cermet particles of a median particle size (D50) of 10-35 ?m, and 15-35 wt % of a dense cemented carbide or cermet particles of a median particle size (D50) of 3-10 ?m. The present invention also relates to a method of making a cermet or cemented carbide body, the method including the steps of forming the powder mixture, 3D printing a body using the powder mixture and a printing binder and thereby forming a 3D printed cermet or cemented carbide green body and sintering the green body and to form a cermet or cemented carbide body.

Abstract: Methods, systems, and apparatus, including medium-encoded computer program products, for designing and manufacturing conformal cooling molds with lattice structures include, in one aspect, a method including: obtaining temperature and pressure data for a 3D model of a conformal cooling mold from computer simulation of injection molding; replacing a volume of the 3D model with a lattice structure to reduce the mass of the mold; adjusting a number of lattice unit cells for the lattice structure in accordance with the temperature data to increase heat conduction from hotter areas of the mold; adjusting thickness(es) of beams forming the lattice structure in accordance with the pressure data to prevent structural failure of the mold; and providing an updated version of the 3D model of the conformal cooling mold that incorporates the lattice structure after adjustment of the number of lattice unit cells and the thickness(es) of beams forming the lattice structure.

Abstract: An article includes a body that has a solid shell that encloses an interior region. The interior region has a solid sub-region, a lattice sub-region, and a hollow sub-region that are exclusive of each other and distributed based on load path. In an example, the article is a spoiler cap, such as for the spoiler on a vehicle.

Abstract: The invention concerns a method of manufacturing an ophthalmic lens, comprising the steps of providing, mounting and blocking a substrate (10) on a machining support unit (65), surfacing an upper face (12) of said substrate, edging a peripheral edge (13) of said substrate, wherein said machining support unit comprises a surfacing member (40) and an edging member (30) which are separable, said surfacing member having a cavity (51) in which said edging member is located during said step of surfacing, said surfacing and edging members being configured so that said substrate is mounted and blocked on said machining support unit in a first predetermined position for the surfacing and the edging and, between said steps of surfacing and edging, the method comprises the step of withdrawing said surfacing member from said machining support unit by retaining said substrate on said edging member.

Abstract: A method for producing a three-dimensional object includes specifying reference-object information which describes data of a reference object, determining load information which describes at least one load value in a specific load situation inside the reference object described by the reference-object information, determining load regions having load values that deviate from a reference-load value inside the reference object described by the reference-object information, on the basis of the load information, determining object information which describes geometrically structural data of the object to be produced, on the basis of the load information and of the boundary condition information, and producing the three-dimensional object.

Abstract: An object includes a fluid chamber extending between a first surface and a vertically opposed second surface, the first surface including a fluid passage opening therethrough. A self-breaking support, initially configured to support the first surface, once broken creates a broken support disposed between the first surface and the vertically opposed second surface. The support includes: a base having a first end coupled to the first surface and a second opposing end. The first end of the base is wider than the second end, and a fluid passage extends through the first base for fluidly coupling the fluid chamber and the fluid passage opening in the first surface. A self-breaking link is disposed between the second opposing end of the first base and the second surface.

Abstract: Computer-implemented systems and methods for preparing a virtual three-dimensional (3D) object for 3D printing are provided. A hollowed-out representation of an input model is generated. The input model defines a solid virtual 3D object, and the hollowed-out representation comprises a shell and an internal volume that is a void. The internal volume is meshed to generate a polygonal mesh representation of the internal volume. A lattice microstructure corresponding to the polygonal mesh representation is generated by (i) replacing each edge of the polygonal mesh representation with a solid part, and (ii) uniting the solid parts to form the lattice microstructure. A lightweight representation of the input model is generated, where the lightweight representation comprises the shell and the lattice microstructure.

Abstract: A casting method includes constructing a 3D model to add an inner wall compensation quantity, making a thin shell mold by a 3D printing machine, individually treating the thin shell mold by smooth processing, processing the thin shell mold by multi-layer impregnation slurry or gunite to make an outer shell mold, and to form a double-layer shell mold which includes the thin shell mold and the outer shell mold, processing the double-layer shell mold by sand filling and compressing, clearing the thin shell mold by a physical or chemical process, casting the outer shell mold to form a shaped article, and post processing the shaped article by shaking and sand clearing to form a product.

Abstract: A structure and method are provided for forming a box for molding an article for use in casting. A wall defines a cavity formed in a shape of the article and configured to receive a material for forming the article. A rim is disposed around the wall and extends therefrom defining a hollow back on an opposite side of the wall from the cavity. A lattice structure formed in the hollow back and is connected with the wall and with the rim. The box may be formed by additive manufacturing.

Abstract: The primary object of the present invention is to provide a mold for continuous casting including a temperature detection unit which can detect the temperature of a copper plate of the mold with high precision, and can be easily inserted into and pulled out of the copper plate. The present invention includes: a main body; and a temperature detection unit which is inserted in an insertion hole in the main body, and detects temperature inside the mold. The temperature detection unit includes: an FBG sensor inserted in a protection tube which can be deformed in a radial direction; and a support member which supports the FBG sensor along the longitudinal direction. At a temperature detection point, the protection tube in which the FBG sensor is inserted is held between a stretched member in the support member and an inner surface of the insertion hole.

Abstract: A mold capable of imparting an appropriate amount of heat depending on a part of an object to be heated, the mold for transferring heat to the object to be heated is provided with a hollow portion inside the mold, and a heat amount adjusting agent, which is accommodated in the hollow portion, for changing heat transfer property of the hollow portion, in which the heat amount adjusting agent is made of a powdery or granular material having a material property different from a material property of the mold.

Abstract: A method for manufacturing a light guide plate mold includes: acquiring a deformation coefficient i, where 1<i?1.12, and a size parameter j, where 0.03 mm<j?0.05 mm; applying digital simulation software to simulate a formation process of an original three-dimensional model for a light guide plate so as to acquire a simulation deformation amount of the light guide plate; multiplying the simulation deformation amount with the deformation coefficient i to obtain a counter deformation amount of a light guide plate mold; and subtracting the size parameter j from a length and a width of the light guide plate to obtain length and width dimensions of the light guide plate mold; and forming the light guide plate mold according to the counter deformation amount of the light guide plate mold and length and width dimensions of the light guide plate mold. A light guide plate manufactured with such a mold shows relatively high flatness.

Abstract: In embodiments described herein, it may be determined when to replace a degraded slush mold with a non-degraded slush mold by a method that may comprise monitoring a sample media while repeatedly contacting a surface of the sample media with an abrasive material to determine the number of contactings required to reduce a grain height of the surface of the sample media to a threshold grain height. The repeated contactings of the abrasive solution with the surface of the sample media may reduce the grain height of the sample media. The surface of the sample media may comprise a material substantially identical to the material of at least a portion of a forming surface of the slush mold.

Abstract: A mold comprising a scaffolding support structure including a base member, a top member and side members defining an enclosure. The scaffolding structure further includes a plurality of interconnected and elongated support members interspersed within the enclosure between the base member and the top member so as to define open space within the enclosure for ease of heating and cooling fluid flow, and a plurality of flow partitions within the enclosure. An intermediate layer is formed on the top member and a working surface layer is formed on the intermediate layer.

Abstract: A method of simulating aluminum oxides defects in aluminum castings comprises determining the free surface area for a plurality of particles of aluminum in an aluminum melt, storing the free surface area for each particle of aluminum, tracking the free surface area change during mold filling, and calculating the total area of entrained or surface oxide films based on the free surface area change during mold filling. The method may further comprise a scalar variable method and a discrete particle method coupled together to simulate the aluminum oxide defects in aluminum castings.

Abstract: Methods and apparatus for measuring the cleanliness of molten metals. Direct current is passed between electrodes through molten metal advancing through a passage in an electrically resistive wall. A voltage signal is analyzed for the presence of solid generally non-metallic inclusions in the metal. Direct current is supplied by one or more ultra-capacitors and the decay in discharge voltage of the capacitor(s) is compensated for by passing the current from each capacitor through a resistor ladder network circuit having resistors connected in parallel. Individual resistors are switched on or off in a sequence effective to change the resistance of the circuit and maintain the current within a predetermined range. Heat generation and noise pick-up are minimized by maintaining a low discharge voltage and measurement current while using FETs only in the fully ON or OFF conditions to switch the resistors into or out of the circuits.

Abstract: Disclosed is a method and apparatus for reducing electromagnetic noise pick up in a Liquid Metal Cleanliness Analyzer (LiMCA), used to detect and measure particles in molten metal. A first electrode inserted in the molten metal is electrically insulated from second and third electrodes, also inserted in the molten metal. Molten metal and particles pass between the first electrode and the second and third electrodes through a passage in the electrical insulation. The second and third electrodes have a configuration with respect to the first electrode sufficient to establish symmetrical current loops between the first electrode and the second and third electrodes when a current is supplied to the second and third electrodes. The current is supplied from an ultra-capacitor. Electromagnetic noise in the symmetrical current loops is detected and is added in opposition to reduce the amplitude of the electromagnetic noise.

Abstract: A method for manufacturing hollow ingot for retaining ring of large generator by electroslag remelting, comprising the following steps: (1) preparing consumable electrode assemblies; (2) melting slag into molten slag; (3) inserting one consumable electrode assembly into an electroslag remelting hollow ingot mold; (4) switching on two transformers; (5) pouring the molten slag into the electroslag remelting hollow ingot mold; (6) forming a current circuit among a stub, the consumable electrode assembly and a water-cooled bottom plate; (7) forming a current circuit among the upper segment, the water-cooled bottom plate and the transformer; (8) regulating the output current and voltage of the two transformers; (9) starting a withdrawing device to withdraw; (10) exchanging the consumable electrode assembly; (11) inserting a subsequent consumable electrode assembly into the molten slag, and repeating steps (8) to (10) until withdrawing is completed.

Abstract: A titanium-containing article casting mold composition includes calcium aluminate and an X-ray or Neutron-ray detectable element. A method for detecting sub-surface ceramic inclusions in a titanium or titanium alloy casting includes combining calcium aluminate, an element more radiographically dense than the calcium aluminate, and a liquid to form a slurry; forming a mold having the calcium aluminate and the radiographically dense element from the slurry; introducing a titanium aluminide-containing metal to the radiographically dense element-bearing mold; solidifying the titanium aluminide-containing metal to form an article in the mold; removing the solidified titanium aluminide-containing metal article from said mold; subjecting the solidified titanium aluminide-containing article to radiographic inspection to provide a radiograph; and examining the radiograph for the presence of the radiographically dense element on or in the article.

Abstract: A system includes a first sensor positioned at a first location that senses a pallet identifier associated with a transfer pallet. A component is associated with the transfer pallet. A second sensor positioned at a second location remote from the first sensor senses the pallet identifier associated with the transfer pallet. A marking machine proximate to the second location marks the component with a component identifier associated with component unique birth data based on the pallet identifier.

Abstract: Various embodiments include methods and related systems for laser-assisted casting. Some embodiments include a method including: performing laser ablation on a preliminary wax casting model to form a modified wax model including at least one additional feature absent from the preliminary wax casting model; coating the modified wax model to form a mold shape around the modified wax model; removing the modified wax model to leave a casting mold including the at least one additional feature; forming a shape from a casting material using the casting mold having the at least one additional feature; and scanning the modified wax model to image the at least one additional feature after the performing of the laser ablation.

Abstract: Various embodiments include methods and related systems for laser-assisted casting. Some embodiments include a method including: performing laser ablation to a preliminary wax casting model to form a modified wax model including at least one surface texture element absent from the wax casting substrate; coating the modified wax model to form a mold shape around the modified wax model; and removing the modified wax model to leave a casting mold including the at least one surface texture element.

Abstract: Various embodiments include methods and related systems for laser-assisted casting. Some embodiments include a method including: performing laser ablation to a preliminary wax casting model to form a modified wax model including at least one cooling hole absent from the wax casting substrate; coating the modified wax model to form a mold shape around the modified wax model; and removing the modified wax model to leave a casting mold including the at least one cooling hole.

Abstract: Various embodiments include methods and related systems for laser-assisted casting. Some embodiments include a method including: performing laser ablation to a preliminary wax casting model to form a modified wax model including at least one additional feature absent from the wax casting substrate; coating the modified wax model to form a mold shape around the modified wax model; and removing the modified wax model to leave a casting mold including the at least one additional feature.

Abstract: The position of the molding geometry of an assembled mold relative to a CAD data set is determined so the dimensional accuracy of the cast part to be produced can be evaluated. The position of the molding geometry of a first mold part is measured and compared to a desired position according to a CAD data set. The position is adjusted to optimally adapt it to within tolerances. The first mold part is maintained in its adjusted position while the position of the molding geometry of a second mold part is measured and compared to a desired position according to the CAD data set. The position of the second mold part is adjusted to optimally adapt it to within tolerances. Thereafter, the mold parts are fixed together with a curable molding material deposited into spaces in the mold parts that is allowed to harden.

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.

Abstract: A method of manufacturing a component in a die casting cell that includes a die casting system according to an exemplary aspect of the present disclosure includes, among other things, isolating a first chamber from a second chamber of the die casting system, melting a charge of material in the first chamber, sealing the second chamber relative to the first chamber, and simultaneously injecting the charge of material within the second chamber to cast the component and melting a second charge of material within the first chamber.

Abstract: There are provided a strength evaluation method of a die casting product capable of appropriately evaluating the strength of the die casting product, and a die casting product in which the strength is evaluated by the strength evaluation method. A breakage test is performed by a simple strength tester after casting, and then, a strength reduction ratio is estimated based on an area ratio of cold flakes in a broken surface obtained by broken surface observation. Alternatively, ultrasonic flaw detection is performed for an internal defect in a predetermined range of a high stress portion of the die casting product, calculated by stress analysis in advance, and the die casting product is evaluated to have a predetermined strength when a defect ratio obtained by dividing a total area of the internal defect in the predetermined range by a total defect detection area is less than or equal to a predetermined value.

Abstract: A method of manufacturing a case part using a die with at least one core pin to form the cast part with at least one receptacle, where the method includes an automated inspection process that inspects the receptacle for quality control using a coordinate measurement machine, and where the inspection process can also automatically determine whether the core pin is bent or broken.

Abstract: A mold releasability evaluating apparatus includes a forming die that includes a bottom portion having a main surface, and a wall surface portion that is connected to the main surface of the bottom portion and has a wall surface in which an angle formed with the main surface of the bottom portion is an obtuse angle; an extrusion pin capable of protruding out from the main surface of the bottom portion in a direction that separates a compact from the main surface of the bottom; and a measuring device configured to measure a load applied to the extrusion pin when the extrusion pin pushes the compact away from the main surface of the bottom portion, after one surface of the compact is formed by the main surface of the bottom portion.

Abstract: A method for measuring the temperature in a mold by a fiber-optic measurement method and a correspondingly designed mold. For this purpose, light waveguides, through which laser light is conducted, are arranged in grooves in the outside surface of the copper mold plate. The temperature at several measurement points along the measurement fiber is determined by a temperature detection system. In particular, the method makes it possible to achieve much greater local resolution of the temperature measurements than that achieved by thermocouples.

Abstract: A method is provided of non-destructively inspecting titanium alloy articles in the as-cast condition using ultrasonic waves to detect internal flaws, comprising modification of grain structure in the as-solidified ingot structure by the addition of trace boron to various titanium alloys. The ability to ultrasonically inspect as-cast billets combined with improved hot workability provided by trace boron enhancement permits an economical method of manufacture of titanium alloy articles destined for high performance applications.

Abstract: The Present invention provides an arc melting furnace apparatus and a method of controlling arc discharge, in which a melt material having been melted can be stirred efficiently, avoiding labor intensive work. The furnace is provided with a mold 3 having a recess 3a and provided in a melting chamber 2, a non-consumable discharge electrode 5 for heating and melting a melt material accommodated in the recess 3a, a power source unit 10 for supplying electric power to the non-consumable discharge electrode 5, and a control device 11 which controls the power source unit to control output intensity of the arc discharge from the non-consumable discharge electrode. The control device 11 controls output current from the power source unit 10 and its current frequency to vary the output intensity of the arc discharge from the non-consumable discharge electrode 5 and stir a molten metal resulting from heating and melting the melt material.

Abstract: A chaplet includes a first portion configured to engage one of a core and a mold, a second portion configured to engage the other of the core and the mold, and an elongated rod extending between the first portion and the second portion. The rod has a plurality of breakaway sites for allowing the length thereof to be selectively reduced in predetermined increments.

Abstract: A process for producing formed parts made of an aluminum alloy, including the steps of exposing the aluminum alloy to high shearing forces in a mixing and kneading machine, feeding the liquid aluminum alloy to the working space at one end of the housing and, at the other end of the housing, removing from the working space the liquid aluminum alloy now formed as a partially solid aluminum alloy with a predefined solids content, and processing the partially solid aluminum alloy with the predefined solids content into formed parts, wherein the solids content of the aluminum alloy in the working space is set to the predefined solids content by cooling and heating the working space in a targeted manner. The mixing and kneading machine includes a housing with a working space, a worm shaft including kneading blades and axial passage openings, and kneading projections.

Abstract: The process for investment casting of complex shapes has historically had 6 basic steps in it. Depending upon the path taken, these discrete steps have been reduced to either 5 steps, or to 2 steps, discarding the unwanted steps. Instead of having to generate the shape of each sacrificial pattern, the process generates either (A) a male tree containing a plurality of sacrificial patterns, already on their runners, onto which a mold shell can be formed, or, (B) a female shell, made of a refractory material, and forming internally the outside surfaces of the plurality of patterns and runners. This process removes both capital expenditure for tooling and process time by up to 90%. By removing several lengthy, time-dependant steps from the process the part cost and lead time are reduced.

Abstract: A ring including a shank having platforms at predetermined locations on an outer surface of the shank, where the platforms identify preferred positions for setting gemstones.

Abstract: A process is provided for forming an airfoil for a gas turbine engine involving: forming a casting of a gas turbine engine airfoil having a main wall and an interior cavity, the main wall having a wall thickness extending from an external surface of the outer wall to the interior cavity, an outer section of the main wall extending from a location between a base and a tip of the airfoil casting to the tip having a wall thickness greater than a final thickness. The process may further involve effecting movement, using a computer system, of a material removal apparatus and the casting relative to one another such that a layer of material is removed from the casting at one or more radial portions along the main wall of the casting.