Abstract: Devices may be in contact with molten metals such as copper, for example. The devices may include, but are not limited to, a die used for producing articles made from the molten metal, a sensor for determining an amount of a dissolved gas in the molten metal, or an ultrasonic device for reducing gas content (e.g., hydrogen) in the molten metal. Niobium may be used as a protective barrier for the devices when they are exposed to the molten metals.

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: There is provided a ceramic fiber casting core used in making cast metal parts comprised of a ceramic fiber structure. The casting core may further comprise a support tube in structural supporting relation to the ceramic fiber structure. There is also provided a method to manufacture the ceramic fiber casting core that comprises mixing ceramic fibers and a binder in a mix tank. Pouring the resultant mixed slurry into a vacuum forming tank. Inserting a perforated mandrel into the vacuum forming tank. Forming a vacuum inside the mandrel resulting in vacuum depositing of the ceramic fiber on the mandrel. Removing the ceramic fiber casting core and mandrel from the vacuum forming tank. Removing the mandrel, and then drying and curing the ceramic fiber structure. When necessary, locating a support member in structural supporting relation to the ceramic fiber structure. Machining the unfinished casting core to a desired outside dimensions.

Abstract: The invention relates to investment casting shell molds and their method of manufacture. The method entails mixing fiber such as ceramic refractory fiber and organic fiber with ceramic filler to form a dry blend. The dry blend is mixed with a binder sol such as colloidal silica sol to form slurry. An expendable preform is dipped into the slurry, stuccoed and dried. This step is repeated until a ceramic shell of a desired thickness is formed over the expendable preform. The expendable preform then is removed, and the green ceramic shell is fired. Molten metal then may be poured into the shell to form a metal casting.

Abstract: A ceramic investment shell mold is reinforced with a carbon based fibrous reinforcement having an extremely high tensile strength that increases as the mold temperature is increased especially within the range of casting temperatures employed for casting large directionally solidified industrial gas turbine components. The carbon based fibrous reinforcement is wrapped or otherwise positioned around the repeating ceramic slurry/stucco layers forming the intermediate thickness of the shell mold wall. The reinforced shell mold can be used to cast large directionally solidified industrial gas turbine components with accurate dimensional control.

Abstract: A ceramic casting shell mold having a pre-selected shape comprises alternate, repeating layers of a ceramic coating material and a ceramic stucco, defining a total thickness of the shell mold; and a ceramic-based reinforcing sheet disposed in the alternate, repeating layers of coating material and stucco at an intermediate thickness. The ceramic-based reinforcing sheet comprises a one-piece monolithic, integral body, which comprises a pattern of holes that enhance bonding between the ceramic-based reinforcing sheet and adjacent ones of the alternate, repeating layers of ceramic coating material. The ceramic-based reinforcing sheet conforms to the shape of the mold and providing structural reinforcement to the mold.

Abstract: A ceramic investment shell mold is reinforced with a carbon based fibrous reinforcement having an extremely high tensile strength that increases as the mold temperature is increased especially within the range of casting temperatures employed for casting large directionally solidified industrial gas turbine components. The carbon based fibrous reinforcement is wrapped or otherwise positioned around the repeating ceramic slurry/stucco layers forming the intermediate thickness of the shell mold wall. The reinforced shell mold can be used to cast large directionally solidified industrial gas turbine components with accurate dimensional control.

Abstract: A ceramic casting shell mold having a pre-selected shape is described. It includes alternate, repeating layers of a ceramic coating material and a ceramic stucco, defining a total thickness of the shell mold; and a ceramic-based mat of reinforcing material disposed in the alternate, repeating layers of coating material and stucco. The reinforcing material for the mat is usually made from a ceramic material, and includes fibers having a bi-directional orientation. A method for making a ceramic casting shell mold is also described, as well as articles cast from such a mold, e.g., superalloy articles.

Abstract: A ceramic investment shell mold is reinforced with a carbon based fibrous reinforcement having an extremely high tensile strength that increases as the mold temperature is increased especially within the range of casting temperatures employed for casting large directionally solidified industrial gas turbine components. The carbon based fibrous reinforcement is wrapped or otherwise positioned around the repeating ceramic slurry/stucco layers forming the intermediate thickness of the shell mold wall. The reinforced shell mold can be used to cast large directionally solidified industrial gas turbine components with accurate dimensional control.

Abstract: A ceramic investment shell mold is reinforced with a carbon based fibrous reinforcement having an extremely high tensile strength that increases as the mold temperature is increased especially within the range of casting temperatures employed for casting large directionally solidified industrial gas turbine components. The carbon based fibrous reinforcement is wrapped or otherwise positioned around the repeating ceramic slurry/stucco layers forming the intermediate thickness of the shell mold wall. The reinforced shell mold can be used to cast large directionally solidified industrial gas turbine components with accurate dimensional control.

Abstract: To form a mold for casting a metal article, metal pins are inserted through a pattern. End portions of the metal pins are bent after the pins have been inserted through the pattern. The pattern and opposite end portions of the metal pins are then covered with wet ceramic mold material. A mold structure is formed by drying the wet ceramic mold material. The pattern is then removed from the mold structure to leave a mold cavity with the metal pins extending through the metal cavity between opposite side sections of the mold structure. Molten metal is conducted into the mold cavity and force is transmitted between opposite side sections of the mold structure through the metal pins to retard movement between the side sections of the mold structure. The molten metal is solidified in the mold cavity and a metallurgical bond is formed between the metal in the mold cavity and the metal pins. The cast article is then removed from the mold structure. The cast article has a thin wall section with a thickness of 0.

Abstract: A process for producing structural elements, preferably prototypes, in which a “lost” model, i.e., positive model, of the structural element is produced in a first step and the model is subsequently cast with a molding compound to produce a negative mold. The mold is then used for manufacturing the structural element, preferably a prototype, by casting. The model is cast and/or filled with the molding compound in a plurality of successive steps and the position of the model relative to a reference plane is changed in each of the individual steps of casting or filling.

Abstract: A ceramic investment shell mold is reinforced with a carbon based fibrous reinforcement having an extremely high tensile strength that increases as the mold temperature is increased especially within the range of casting temperatures employed for casting large directionally solidified industrial gas turbine components. The carbon based fibrous reinforcement is wrapped or otherwise positioned around the repeating ceramic slurry/stucco layers forming the intermediate thickness of the shell mold wall. The reinforced shell mold can be used to cast large directionally solidified industrial gas turbine components with accurate dimensional control.

Abstract: A molding machine for producing a mold by applying external force of either pressurized air or mechanical compaction or both to molding sand (12) that is held in a mold space is disclosed. The mold space is defined by a master plate (9), which has a pattern (8), and a flask (7). The molding machine includes a lifter table (11) for vertically carrying the master plate (9) and the flask (7), a filling frame (4) disposed for vertical movement above the lifter table (10), and a reinforcing frame (5) disposed for vertical movement between the filling frame (4) and the lifter table (10). The reinforcing frame (5) and the flask (7) are adapted to approach each other such that the reinforcing frame (5) contacts the outer surface of the flask (7) to reinforce it.

Abstract: A reinforced core for use in metal casting processes, especially directional solidification casting processes, comprises an elongated, thin-walled outer quartz or silica rich tubular member and a carbon base reinforcement disposed in and extending along a length of the tubular member. The carbon base reinforcement can comprise one or more graphite rods cemented together in end-to-end relation or a carbon fiber bundle. The carbon base reinforcement can include an outer carbide surface region by coating or surface reaction.

Abstract: A band-like plate is bent until both ends of the plate meet with each other, and then both ends of the plate are joined by welding so as to make a loop. A pair of first and second inner dies are placed inside the loop while a pair of first and second outer dies are placed outside the loop. The loop is held by the inner and outer dies. At the same time or after that, the loop is pressed by the inner dies when the first and/or second dies move in a given direction.

Abstract: A reinforced tubular core for casting gas turbine engine blades with cooling air passages therein is disclosed. A method of casting is also disclosed in which the blades are directionally solidified to produce columnar grained or single crystal blades and in which non-linear passages can be produced. The problem in producing such articles is that the moulds and cores used in the casting process are held at temperatures in excess of 1500.degree. for long periods and presently used silica cores deform during the process. Stronger cores of alumina or silicon nitride cannot be easily bent were believed to be non-leachable from the casting. The present invention provides a core having a tubular silica sheath with a solid alumina rod inside it for support. The sheath can be bent and the straight alumina rods can be inserted from opposite ends of the sheath.

Abstract: This invention relates to a method for reinforcing and repairing cast iron molds by surrounding the mold with a closely fitted steel plate or plates, connecting the ends of the steel plate or plates to form a continuous band, attaching the continuous band to the cast iron mold and locating spacers between the cast iron mold and the continuous band to elevate the band from the cast iron mold wall surface. This invention further relates to a method for reducing shear stress on the means by which the continuous band is attached to the mold by locating the means of attachment around a corner from the source of stress at an obtuse angle to the mold wall being reinforced.

Abstract: The invention relates to floats and to a process for manufacturing floats for the continuous casting of metal alloys and particularly aluminum and alloys thereof, said floats being formed by assembling machined parts of compressed panels of alumino-silicate ceramic fibers having a voluminal mass above 0.45 g/cm.sup.3, in which the surfaces which come into contact with the molten metal alloy are coated with a suspension of metallic oxides in a mineral hardener.

Abstract: A precision investment casting ceramic mold of the self-casting type is made as a unitary mold by providing separately a pattern for a wax charge-holding assembly and a pattern for a wax article casting assembly, each including an alignment portion. The two patterns are secured together at the alignment portions and are supported and located one with respect to the other by a plurality of supporting and locating members. The assembled patterns then are used in the conventional manner to make a ceramic casting mold.