Abstract: A casting core assembly (140) includes a metallic core (144, 146, 148; 360; 380; 400) and a ceramic core (142). A protuberant portion (184) of a metallic core is received in compartment (186) of the ceramic core.

Abstract: A method for protecting a turbomachine from corrosion may include creating a first sand mold in a drag of a casting flask, coupling a cope of the casting flask to the drag, removing the runner pin and the at least one riser pin from the cope to expose a runner and at least one riser, respectively, and pouring a molten first material in the runner to cast a first component of the turbomachine. The method may further include removing the first sand mold, creating a second sand mold utilizing the first component in the drag, coupling the cope to the drag, removing the runner pin and the at least one riser pin from the cope to expose a runner and at least one riser, respectively, and pouring a molten second material in the runner to cast a second component of the turbomachine integral with the first component.

Abstract: An intermediate case (IMC) for use in a compressor section of a gas turbine engine includes a bleed duct and an IMC centerbody. The bleed duct is formed via sand casting. The IMC centerbody is formed via investment casting and is fixedly attached to the bleed duct.

Abstract: A multi-wall ceramic core for casting an airfoil with one or more internal cooling passages is made by preforming at least one fugitive core insert to have a joint-forming surface with a male and/or female joint feature and then forming at least one fugitive core insert in-situ adjacent and integrally connected and fused to the at least one preformed core insert at the joint-forming surface to form an interlocked, fused joint to form a composite core insert that includes features to form internal passage surfaces in the core when the composite core insert is removed. Another aspect involves preforming first and second fugitive core inserts to have respective joint-forming surfaces with respective snap-fittable joint features and assembling the first and second fugitive core inserts to form a composite core insert by snap fitting the snap-fittable joint features together to form an interlocked joint.

Abstract: A composite core die includes a reusable core die; and a disposable core die. The disposable core die is in physical communication with the reusable core die and surfaces of communication between the disposable core die and the reusable core die serve as barriers to prevent the leakage of a slurry that is disposed in the composite core die.

Abstract: Disclosed is a foundry mix containing a sulfate and/or nitrate salt and its use to make foundry shapes by the warm-box, hot-box, no-bake, and cold-box process, the use of these foundry shapes to make metal castings, and the metal castings prepared by the process.

Abstract: A method for manufacturing a bolster of a railway car truck includes providing a drag portion and a cope portion of a mold. In a main body section of the mold, a parting line that separates the drag portion from the cope portion is substantially centered between portions of the mold that define brake window openings in sides of the bolster. One or more cores are inserted into the mold and a molten material is poured into the mold to thereby case the bolster.

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

Abstract: A diesel piston with a cast bi-metallic dome and a method of making the piston. In one form, the dome may include a laminate of a relatively high-temperature material, for example, stainless steel, and a relatively low temperature material, for example, aluminum or aluminum alloys, such that the portion of the dome made from the relatively high-temperature material is directly exposed to combustion within a cylinder into which the piston is placed. In another form, an aluminum coated stainless steel ring is used to form the dome. In one form, an ablation casting process may be used to manufacture the dome.

Abstract: The pattern has a pattern material and a casting core combination. The pattern material has an airfoil. The casting core combination is at least partially embedded in the pattern material. The casting core combination comprises a plurality of metallic casting cores. Each metallic casting core has opposite first and second faces and a respective portion along the trailing edge of the airfoil. At least two of the metallic cores have sections offset between the pressure side and the suction side.

Abstract: A method of forming a hollow sand core involves placing a preform into a cavity defined in a mold, where the preform has a predetermined configuration. A granular material is then introduced into the mold cavity and around the preform. The introduced granular material is established around the preform to form the hollow sand core. The preform is deformed in a manner sufficient to enable removal of the preform from inside the hollow sand core, and then is removed from the sand core. The removal of the preform exposes a hollow portion of the sand core.

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

Abstract: The invention relates to a method and to a device for sing out this method, during which the shell molds (3) are filled with a melt (11) in a clocked manner, the respectively required amount of melt being currently provided at the same time. The casting process ensues by marrying the crucible (6), which is filled with a melt (11), with a shell mold (3) so that the crucible (6) and shell mold (3) form a common cavity (10), and this arrangement is subsequently tilted 180°, so that the melt (11) falls into the shell mold (3).

Abstract: A method of making a wax mold for a golf club head includes the steps of: a) positioning a male die in a cavity of a female die; b) injecting and filling dissolvable wax into a gap between an outer surface of the male die and an inner surface of the female die; c) cooling and solidifying the dissolvable wax in the gap to obtain a wax shell; d) removing the wax shell from the male die and the female die, the wax shell being provided with a hole extending through inner and outer surfaces of the wax shell; and e) inserting a wax plug into the hole to form the wax mold.

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

Abstract: Disclosed is a foundry mix containing a carbonate salt and its use to make foundry shapes by the warm-box, hot-box, no-bake, and cold-box process, the use of these foundry shapes to make metal castings, and the metal castings prepared by the process.

Abstract: Disclosed is a foundry mix containing a sulfate and/or nitrate salt and its use to make foundry shapes by the warm-box, hot-box, no-bake, and cold-box process, the use of these foundry shapes to make metal castings, and the metal castings prepared by the process.

Abstract: A method of forming a hollow sand core involves placing a preform into a cavity defined in a mold, where the preform has a predetermined configuration. A granular material is then introduced into the mold cavity and around the preform. The introduced granular material is established around the preform to form the hollow sand core. The preform is deformed in a manner sufficient to enable removal of the preform from inside the hollow sand core, and then is removed from the sand core. The removal of the preform exposes a hollow portion of the sand core.

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: The pattern has a pattern material and a casting core combination. The pattern material has an airfoil. The casting core combination is at least partially embedded in the pattern material. The casting core combination comprises a plurality of metallic casting cores. Each metallic casting core has opposite first and second faces and a respective portion along the trailing edge of the airfoil. At least two of the metallic cores have sections offset between the pressure side and the suction side.

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

Abstract: The object of the present invention is to provide a mold which has low reactivity with molten alloys and which is inexpensive, a method for manufacturing the same and a molded article using the mold. A mold 40 in accordance with the present invention serves for manufacturing a molded article 60 of a titanium-aluminum alloy or a titanium alloy. At least an initial layer 44a of a cavity surface 43 of a mold body 41 constituting the mold 40 is formed of a calcined product of a slurry comprising a filler having cerium oxide as a main component and a binder having silica sol as a main component.

Abstract: At least one feed core 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 method is provided for removing a fugitive pattern, such as wax or other meltable pattern material, residing inside of a refractory mold by discharging condensable vapor such as steam inside the mold to contact and melt the pattern while an exterior of the mold is subjected to a non-condensing gas atmosphere such as air outside of the mold wherein the condensable vapor inside the mold and the atmosphere outside of the mold are at substantially the same pressure. Condensable vapor is condensed inside the mold where the vapor has contacted the pattern while the exterior of the mold remains free of condenate. The condensed vapor and melted pattern material are drained out of the mold. The condensed vapor can be discharged initially inside a hollow sprue of a fugitive pattern assembly to melt the sprue and then inside the mold to melt the patterns of the pattern assembly.

Abstract: At least one feed core 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 microwave-based process for dental casting includes the use of microwave radiation to obtain burnout of a wax pattern from an investment mold. Phosphate-based, thermal investment materials have been found suitable for use in the process.

Abstract: A method of manufacturing a brake pad comprising casting a back plate in a mould. The plate is formed with at least one integral projection which overhangs an adjacent surface of the plate. The mould is formed from frangible material and has a recess in the shape of the projection. The mould is formed from particulate material compressed around a projection made of resilient material which deforms to the shape of the projection. The resilient material is withdrawn to form the recess. Metal is cast in the mould including the recess. After solidification of the metal, the mould is broken away from the projection. The method also comprises pressing a mixture containing friction material and curable material against the plate including pressing the mixture around the projection so that it extends beneath the overhang and curing the curable material to form a block of friction material adhered to the plate.

Abstract: A mold for a prototype metal casting or the like may advantageously be made by forming a casting pattern of adhesively bonded aggregate particles using a binder containing a principle constituent that is soluble in supercritical carbon dioxide; forming a rigid shell mold about the pattern of materials that are unaffected by supercritical carbon dioxide; thereafter exposing the pattern and mold combination to supercritical carbon dioxide to remove the pattern binder adhesive and leave unbonded aggregate particles in the mold and removing the aggregate particles from the mold to leave a mold cavity that faithfully defines the pattern shape.

Abstract: A casting mold member is produced from a master which has a section with a spirally symmetrical outer contour such that the casting mold member surrounds the section in an azimuthally closed manner with respect to the axis of symmetry. The casting mold member is used to provide a casting mold. The casting mold member is filled by feeding a cast iron melt, and solidifying the melt by using a graphitization pressure to prevent cavities and pores in the casting and by chilling the melt to obtain shell hardening.

Abstract: The invention relates to a water based binder for use in a slurry for investment casting. The binder includes a mixture of a colloidal silica sol and at least one latex polymer. The latex polymer is preferably an acrylic latex or a styrene butadiene polymer (or a combination of these) which reduces the processing time between dips during shell mold making for investment casting. The latex polymer further lowers a critical concentration point or gelation point of the colloidal silica sol. The binder may be used as a primary binder or a backup binder in the shell mold making process. To make the slurry, the binder is combined with at least one refractory powder, preferably a refractory powder selected from the group of: aluminosilicates, fused silica, quartz silica, alumina, zircon, and zirconia.

Abstract: A drag bit with a faceted profile and method of its manufacture by which the facets provide for planar mold surfaces upon which cores having planar ends can completely contact the surface of the mold. The invention is particularly though not exclusively adapted to matrix body drag bits incorporating PDC cutters having tungsten carbide studs or cylinders which are mounted in wings, ribs or blades of the bit body. In accordance with a preferred embodiment of the present invention, the wings, ribs or blades have a small planar surface or facet at each PDC cutter location with each of the facets being at a consistent angular disposition with respect to the axis of the corresponding cutter stud. The facets are created by flat mold surfaces which facilitate the proper positioning and angular disposition of the cores which form the openings in the matrix for receiving the PDC cutters.

Abstract: A helical compressor having hollow male and female rotor components of the type used as a supercharger for an internal combustion engine. The compressor is provided with a manifold plate which cooperates with the manifold to evenly distribute the high pressure discharge from the compressor throughout the associated plenum or manifold. The hollow rotor components are cast by full mold casting techniques in which an expendable foam pattern is first made in a metal mold and then placed in a sand-filled flask and poured with an appropriate foundry metal. The interior and exterior surfaces of the rotor pattern parts having helically extending lands and grooves permitting helical ejection of the pattern parts from the mold.

Abstract: In an investment casting process wherein molds or cores are prepared by forming them around a polymer pattern and then dissolving the pattern with a solvent, solvent losses can be reduced by heating the mold or core before contacting it with the solvent to reduce the amount of solvent adsorbed in the mold or core. An improved process comprises: (a) forming the mold or core around the pattern; (b) heating the mold or core; (c) dunking or spraying the mold or core with the solvent until the pattern is dissolved; (d) placing the mold or core in a drying chamber in the path of circulating heated air; (e) cooling the air to condense the solvent; (f) recovering the condensed solvent; and (g) reheating the air until it is no longer saturated with solvent and recycling the air to the drying chamber. The preliminary heating step can reduce solvent losses by 66 percent and the entire improved process can reduce solvent losses by about 90 percent.

Abstract: A method of preparing a template for a product from a sample of the product. The ultimate template is either larger or smaller in size than the sample. Initially, a mixture of liquid rubber and a curing agent is prepared. The sample is then covered with the mixture and the mixture is permitted to harden to form a temporary mold. The sample is then removed from the mold to form a cavity, and the size of the cavity in the mold is altered to either increase or decrease its dimensions. Finally, a hardenable material, such as an epoxy resin, is poured into the mold to form the template. If an enlarged template is to be formed, the size of the cavity of the mold is increased by immersing the mold in an organic solvent bath. If the size of the mold is to be decreased, an organic solvent is added to the mixture before formation of the mold, and after the mold has been formed, it is heated to shrink the size of the mold.

Abstract: A process for production of castings is provided employing patterns combining gasifiable pattern parts, for the creation of nonconforming contours, with reusable pattern parts. After molding, only the reusable pattern parts are removed from the mold, while the gasifiable pattern parts are destroyed during casting.

Abstract: An investment casting process employs a low-cost plastic pattern manufactured by machining. A mold is cast around the plastic pattern following which the pattern is removed from the mold to leave a mold cavity which molten metal or the like may be poured to produce a finished part. Reusable plastic patterns may be formed by casing silastic rubber. The silastic rubber patterns may be mechanically separated from the mold without damaging the pattern.

Abstract: A method and an apparatus for replacing pattern plates in a moulding plant for making boxless mould parts of sand or other like material is characterized by the use of a revolving table (1), which is provided with e.g. four symmetrically placed arms (1), in which are suspended pattern plates (2,3). The revolving table is designed for sequential conveying of the pattern plates (2,3) for placing these on a squeeze plate (PP) and a counter-pressure plate (MTP), respectively, in the moulding chamber of a moulding plant (suggested only on the drawing). The pattern plates (2,3) are placed in the respective arms (1) when the latter are just opposite the changing position. From the changing position, the pattern plates (2,3) are conveyed into a moulding chamber by a transverse sliding movement in an essentially known manner.

Abstract: Process for the production of precision castings with well-defined reproduction of detail and a great accuracy of measurement, by which the pattern to be reproduced is equipped with a drainage apparatus, having at least one duct extending outside the molding box, and the molding material containing phosphate as the bonding agent is poured in the molding box and solidified. After the pattern is removed from the solidified mold, by the introduction of compressed gas, the water of the solidified material is pressed out, and after calcining at a temperature of at least 250.degree. C., the mold is connected to a vacuum line and evacuated. The molten metal mass is then poured into the mold while the vacuum is maintained and solidified.

Abstract: A device for changing model plates is used in the manufacture of sand molds for foundry molding machines. The vertical axis of the lifting mechanism intersects both the longitudinal axis of the feed mechanism and the pivot field circle of the rotary conveyor for moving the model plates between lifting and molding sites. Model plates can be changed by the device without interrupting the molding machine cycle. Also, the model plates can be positioned outside the molding machine.

Abstract: A foundry mold making machine is so designed that at the start of the process of moving the pattern assembly clear of the mold, compressed air is supplied through the pattern assembly until a gap or narrow space has been formed between the mold and the pattern. In this respect an air-tight connection is maintained between the pattern plate support and the flask until the compressed air supplied to the gap has been relaxed. In this way it is possible to make certain that there is no damage to the edges of the mold by suddenly letting off air.

Abstract: A process for making an investment mold wherein a paste composition is used as the separating layer between the investment mould of refractory material and the surface of the metal container in which the investment mould itself is located. The composition is constituted by an organic component which can be eliminated by thermal degradation at temperatures above 200.degree. C. and a refractory mineral component which is stable at the casting temperature of the alloy used in the casting process. In a preferred embodiment, the composition comprises vaseline, talc and kaolin.

Abstract: A casting process for making and utilizing an elastomeric pattern that is coated with a non-metallic material to form a non-metallic shell mold and thereafter removed from the non-metallic shell mold by thermal decomposition or mechanical stripping.

Abstract: In a method of forming a thin (<2 .mu.m) unbacked metal foil having a desired curviplanar shape, a soluble polymeric film, preferably comprising polyvinyl alcohol, is formed on a supporting structure having a shape that defines the desired shape of the foil product. A layer of metal foil is deposited onto one side of the soluble film, preferably by vacuum vapor deposition. The metallized film is then immersed in a suitable solvent to dissolve the film and thereby leave the metal foil as an unbacked metal foil element mounted on the supporting structure. Aluminum foils less than 0.2 .mu.m (2,000 .ANG.) thick and having an areal density of less than 54 .mu.g/cm.sup.2 have been obtained.

Abstract: A match plate mold-producing apparatus is provided with at least a pair of molding flasks for an upper and a lower sand mold. The pair of molding flasks is alternately positioned in a first mold-forming station in which a match plate carrying thereon a pattern or patterns is vertically held between a pair of squeezing devices movable toward and away from one another along a horizontal axis, and in a second mold-removing station in which mold-jointing operation and mold-removing operation are carried out by cooperation of a vertically movable flask-support device, a vertically movable mold-support device and a vertically movable mold-removing device.

Abstract: A mold forming tool for use in the manufacture of casting molds by compression of loose mold forming material by a process in which the final compacting is achieved by pressing, for the casting of cast pieces having undercuts, the tool having an elastically deformable portion in the region of the undercuts, and the elastically deformable portion being made of a material which is deformable, thus creating the undercut pattern, solely under the influence of the pressure exerted on the mold forming material during the final compacting.

Abstract: A sand core pattern (11) for producing a one-piece cast wheel (10) having a radially inner shell (12), a radially outer blade support (13), and a plurality of angled blades (14) extending in a spaced, annular array (22). The pattern includes a plurality of similar segments (15), each having an inner end portion (18) defining a portion of the profile of the shell, and an outer end portion (21) defining the profile of the blade. The segments are supported in annular array about a mandrel (25) and are circumscribed by a split ring (26) defining the pattern for the outer blade support portion of the wheel (10). The inner portions of the segments are defined by angled side surfaces (16,17) which, in alternate ones of the segments in the annular array, converge and diverge toward the center of the array.

Abstract: Disclosed is an improved method for making molds and mold components for use in casting single crystal articles. According to the improved method, a preformed and reusable replica of a mold growth cavity and crystal selector passage is provided, the replica including a cylinder in the form of the desired growth cavity and a helical strand in the form of the desired crystal selector passage, one end of the strand being attached to an end of the cylinder such that their axes are coincident. In one embodiment, the replica is coated with a thin layer of wax or other removable material and then utilized in a variety of mold making processes, including investment molding, to form a growth zone and helical crystal selector in the mold.

Abstract: A method for forming casting molds, comprising forming a flexible pattern composed of rigid plates and a flexible cloth, the rigid plates being adhered to the flexible cloth with intervals between plates, and the flexible pattern being made an air-tight construction, pouring a fluid into the flexible pattern or supplying the fluid under pressure to form any desired shape thereof, discharging the fluid from the flexible pattern after a sand mold has been cured, and then withdrawing the flexible pattern from the sand mold.