Abstract: System and methods involving pattern molds are provided. In this regard, a representative system includes a mold assembly unit having a movable fixture holder operative to engage a portion of a pattern mold and position the pattern mold for assembly.

Abstract: A process for creating a lost wax tree, including the steps of assembling a wax tree having a wax pattern and a wax runner, using automated equipment to flex either the wax tree or the wax pattern to bring disconnected sections into proximity, heating at least one of the disconnected sections, contacting the disconnected sections and then moving the sections slightly away from one another. A process for casting a part including the steps of creating a lost wax tree and where the wax tree is later covered with a mold material and the wax tree is removed to create a mold, the mold is then used to cast a part similar to the wax pattern. A lost wax tree having a wax tree with a wax pattern and a wax runner, automated equipment for flexing, a heating element, and automated equipment for manipulating disconnected sections.

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: A method for producing a casting die by simple work without requiring any high work skill in which the working days required for producing the casting die can be shortened greatly. A die model suitably employed in this production method, an NC processing system and a processing robot are also provided.

Abstract: The manufacture of a submillimetric grid includes the production of a mask having submillimetric openings, referred to as a network mask, on the main face, from a solution of colloidal nanoparticles with a given glass transition temperature Tg, the drying of the masking layer at a temperature below the Tg; the formation of the electroconductive grid from the network mask including in this order: deposition of at least one electroconductive material, referred to as grid material, having an electricity resistivity of less than 10?5 ohm.cm; removal of the masking layer, revealing the mother grid; optional deposition, by electrodeposition, of an electroconductive material, referred to as overgrid material, the surface subjacent to the mother grid then being dielectric; a detachment, of the mother grid or the overgrid, of a thickness of at least 500 nm. The invention also relates to the detached grid.

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 foam material comprises a liquid polymer and a liquid isocyanate which is mixed to make a solution that is poured, injected or otherwise deposited into a corresponding mold. A reaction from the mixture of the liquid polymer and liquid isocyanate inside the mold forms a thermally collapsible foam structure having a shape that corresponds to the inside surface configuration of the mold and a skin that is continuous and unbroken. Once the reaction is complete, the foam pattern is removed from the mold and may be used as a pattern in any number of conventional casting processes.

Abstract: If a refractory metal core (RMC) is punched, the punching asymmetry may be reflected in an asymmetry of the cast article features cast by the punched features. The punched features may have a shear zone and a fracture zone. The shear zone of the RMC will cast a relatively narrow portion of the post near one end; whereas the fracture zone will cast a relatively broader portion near the other end. The broader portion will also have a relatively shallow transition to the adjacent face of the slot-like passageway cast by the RMC. Where there is a stress asymmetry in the cast article in-use, the punching direction may be chosen so that the relatively broad portions of the post fall along the relatively higher stress face of the passageway.

Abstract: A sprue former of the type used to produce a casting mold includes a generally hollow body or a body having hollow sections. The body includes an inlet forming member and at least one first interface member. The inlet forming member is configured to provide an inlet cavity in the casting mold to enable casting material to enter the casting mold. The first interface members are configured to couple to casting patterns. The casting patterns represent items to be cast. The body can also includes a reservoir forming member and at least one connecting member coupling the reservoir forming member to the inlet forming member.

Abstract: A composite element is provided. The composite element includes a ceramic component defining a cavity having a first end and a second end, and a metallic component comprising a head and a body. At least a portion of the body of the metallic component is disposed in the cavity, and the head of the component is disposed on the first end of the cavity. A cross-sectional area of a portion of the body is greater than an area of the first end. In addition, the ceramic and metallic components are interlocked. Methods of making a composite element and of making a clearance sensor part are also provided.

Abstract: A method of forming a pattern includes providing an actual core having dimensions which are different from dimensions of an ideal core. A best fit spatial relationship of the actual core to a spatial envelope for an ideal core is determined. Locating surfaces in a die are moved to positions, at least some of which are offset from ideal core locating positions, in which the actual core is positioned in a best fit spatial relationship with the spatial envelope for the ideal core. A plurality of motors may be utilized to move the core locating surfaces to desired locating positions. The actual core is positioned in engagement with the core locating surfaces and a flow of wax is conducted into the die. If desired, a best fit spatial relationship of the actual core to a die cavity may be determined, rather than a best fit with an ideal core.

Abstract: In an investment casting procedure using microwave energy as the heat source virgin wax models are attached to a spree of wax-type pattern material incorporating a susceptor, the spree having a pour cup also of a wax-type pattern material, the pour cup material having a higher percentage of the susceptor than the material of the spree. In use the pour cup will melt first and the spree second, unblocking the path of the virgin wax so that its expansion will not crack ceramic with which it has been coated.

Abstract: A method of producing sharp tips useful for scanning probe microscopy and related applications is described. The tips are formed by deposition into a mold(s) formed in a sacrificial crystalline semiconductor substrate with an exposed {311} surface which has been etched with a crystallographic etchant to form a 3-sided, trihedral or trigonal pyramidal mold(s) or indentation(s). The resultant tips, when released from the sacrificial mold material or substrate, are typically formed in the shape of a trigonal pyramid or a tetrahedron. Another embodiment involves starting with a {100} surface and the formation of two tips on opposite ends of a wedge at trigonal or trihedral points of the wedge. These tips are less susceptible to the tip wedge effect typical of tips formed using known methods.

Abstract: A method of forming a gating fixture for a lost wax casting process includes determining an optimal orientation of a gate in relation to a part, and forming a fixture that can repeatably be used to consistently locate the gate relative to the part. In one example, stereolithography is used to form the fixture.

Abstract: A method for producing a pattern for the precision-cast representation of a component having a cavity is provided. In the method wherein the component is a turbine component having a cavity, the finished pattern comprises a core and an outer contour pattern, the outer contour pattern at least partially surrounds the core and at least partially defines the outer contour of the turbine component. The core is produced from a curable core material, which cures during the course of the method, and the outer contour pattern is produced from a material which can be burned or melted out. In this case, first the outer contour pattern is produced with a cavity corresponding to the cavity of the turbine component and subsequently the curable core material is filled into the cavity and cured to produce the core.

Abstract: A process of making a cast metal product and a product made utilizing this process. A pattern used for casting the metal panel is prepared utilizing computer-aided manufacturing software to which a digital representation of an image is inputted. The software then determines a tool path height for each digital element of the digital representation. A pattern blank is placed on a computer-controlled routing table which routs the blank utilizing the tool path determined by the software program to form a three-dimensional representation of the desired image on the pattern.

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

Abstract: A method involves forming a core assembly. The forming includes molding a first ceramic core over a first refractory metal core to form a core subassembly. The subassembly is assembled to a second ceramic core.

Abstract: Dental appliances including multiple components and a system and method for constructing the same are disclosed herein. The dental components are designed to fit together to form the dental appliance. The components of the dental appliance are electronically modeled, printed, and pressed sequentially, separately, or as a unitary piece. Forming the dental appliance from multiple components enables each component of the dental appliance to be formed from a different material, each material having different features associated with it. In various embodiments, different materials have different colors, textures, opacities, and transformation factors associated with them. Furthermore, each component can be formed from multiple components. In some other embodiments, a support structure is designed and constructed in order to minimize deformation of a dental component during fabrication of the component.

Abstract: A gas turbine engine component has a leading edge and a trailing edge and a pressure side and a suction side. The pressure side and suction side extend between the leading edge and trailing edge. One or more cooling passageways extend through the airfoil and comprise a trunk extending from an inlet. At the inlet, there is an additional passageway adjacent the trunk and having at least one edge recessed relative to the trunk.

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 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 and system for creating an article of jewelry that contains an anatomical image using a digital image of an anatomical body part such as a fingerprint, handprint, footprint, or the like to create a computer numeric controlled (CNC) software program that drives a machine for producing a wax model of the anatomical image. The wax model is used in a lost wax casting process to create a casting that is used in an article of jewelry. The present invention further provides an article of jewelry containing a novel bail assembly for attaching the article of jewelry to a chain or the like in an aesthetically pleasing manner that hides the attachment hole of the casting.

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: A method is disclosed for molding a component with at least one microstructured functional element, which is configured intentionally with a defined structure, in relief, at a defined point on the surface of the component in order to specifically fulfill a function. The element has a characteristic dimension in the micrometer range in at least one spatial direction. The component is shaped from a substantially metallic material using a mould. At least one functional element is formed in a negative impression that is configured on the surface of the mould.

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 lost-wax cast impeller for a supercharger having no parting line on a hub surface and a blade surface in each space demarcated by pairs of long blades adjacent to each other and having excellent aerodynamic performance. A method of manufacturing the impeller involves forming a lost form pattern in substantially the same shape as the impeller, forming a mold by eliminating the lost form pattern after the lost form pattern is coated with a refractory, and pouring a molten metal in the mold for casting. In the molding step, lost material is injection-molded in a space demarcated by radially arranging, toward a center shaft, a plurality of slide molds having short blade-shaped bottomed groove parts and space shapes between the pairs of long blades adjacent to each other, and the slide molds are released by moving in the radial direction of the center shaft while rotating.

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: 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 method of forming a pattern includes providing an actual core having dimensions which are different from dimensions of an ideal core. A best fit spatial relationship of the actual core to a spatial envelope for an ideal core is determined. Locating surfaces in a die are moved to positions, at least some of which are offset from ideal core locating positions, in which the actual core is positioned in a best fit spatial relationship with the spatial envelope for the ideal core. A plurality of motors may be utilized to move the core locating surfaces to desired locating positions. The actual core is positioned in engagement with the core locating surfaces and a flow of wax is conducted into the die. If desired, a best fit spatial relationship of the actual core to a die cavity may be determined, rather than a best fit with an ideal core.

Abstract: A neck ring for molding a glass container neck finish that includes at least one closure attachment feature. The neck ring includes two semi-annular bi-metal neck ring halves, each consisting essentially of a neck ring insert of wear-resistant metal construction, and a neck ring body of heat-conductive metal construction different from said wear-resistant metal construction and formed around said neck ring insert so as to embed it in said neck ring body. Each of said neck ring halves has a glass-contacting cavity face that includes a first surface portion formed by said inserts for molding the at least one closure attachment feature on the neck finish, and a second surface portion formed by said bodies for molding portions of the neck finish excluding the at least one closure attachment feature.

Abstract: Methods for forming an integral porous region in an orthopedic implant are provided. The method uses an orthopedic implant pattern, together with a porous framework having a plurality of reticulated interstices in a molding technique. After filling the mold with a molten metal such that the molten metal enters at least a portion of the reticulated interstices, followed by cooling, an orthopedic implant is formed. The porous framework is then removed to expose an integral porous region of reticulated porosity in the implant. The orthopedic implant may comprise a monolithic metallic body having an integral porous metal region. Reticulated porosity extends into the monolithic metallic body and is adapted to allow living tissue growth therein.

Abstract: A method of casting a refractory article. The method includes providing a mold formed from a slurry composition comprising plaster and fibers and adding a refractory composition to the mold. The method also includes allowing the refractory composition to set. The refractory composition comprises colloidal silica.

Abstract: In the case of a one-piece lost mould for metal castings 4 of a set moulding material which encloses a mould cavity and has at least one metallic cooling channel 6 that is embedded in the moulding material and carries a cooling medium, portions of the outer side of the metallic cooling channel 6 are uncovered and/or only slightly covered by the moulding material in the direction of the mould cavity.

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

Abstract: A method of forming a gating fixture for a lost wax casting process includes determining an optimal orientation of a gate in relation to a part, and forming a fixture that can repeatably be used to consistently locate the gate relative to the part. In one example, stereolithography is used to form the fixture.

Abstract: A challenge of the present invention is to develop a method for repeatedly forming a reverse transferred pattern in a simple and efficient manner onto the surfaces of Zr based, Ti based, Cu based, Ni based and Fe based metallic glass that have supercooled liquid temperatures of not lower than 400° C. and are also required to be molded at not lower than 400° C. (a) An image pattern is converted into bitmap data being mirror reversed with respect to a real image, (b) high energy density light 15 is repeatedly flashed, and the surface of a mold 20 is scanned while one of dot holes 24 is formed by one-time irradiation, to form an image pattern as dots assembled pattern 21 onto the surface of the mold 20 in accordance with the bitmap data, and (c) the dots assembled pattern 21 is reverse-transfer molded onto a metallic glass 1 within a supercooled liquid temperature range Tg-Tx by means of the mold 20 which is for dots assembled pattern formation.

Abstract: Embodiments of the disclosure provide methods, apparatus, and articles for making a plurality of molds described by CAD data in machine readable form using a reusable mold-forming device. Various embodiments include configuring a plurality of adjustable actuators fixed to a base of a mold-forming device, where the top surface of the adjustable actuators takes the form of the mold required to make the part described by the CAD data. The adjustable actuators may then be readjusted to form another mold surface.

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

Abstract: A wax or similar material may be molded to a base plate of an investment casting shelling fixture. The molding may provide for enhanced positioning of wax patterns or may provide a precise surface shape for the shell.

Abstract: A turbocharger system for an internal combustion engine includes at least one compressor wheel. The at least one compressor wheel of a single stage or multiple stage turbocharger system is formed, such as by pressure casting, from at least one of an aluminum metal matrix composite and an aluminum alloy containing up to 5 weight percent scandium.

Abstract: A heat exchanger element obtained by sand casting, having a modular structure and comprising a right head module, a left head module, and at least one optional intermediate module.

Abstract: A process for casting a turbine engine component is provided. The process comprises the steps of placing a refractory core assembly comprising two intersecting plates in a die, encapsulating the refractory core assembly in a wax pattern having the form of the turbine engine component, forming a ceramic shell mold about the wax pattern, removing the wax pattern, and pouring molten material into the ceramic shell mold to form the turbine engine component.

Abstract: A process and casting media composition for casting three-dimensional parts and sacrificial models from a class of foaming casting compounds, and creating the foaming casting compounds by combining a radiation activated catalyst that causes a phase change from liquid to solid in the material and a foaming agent. In an alternate embodiment the combination is of a cold foaming casting compound and a compound which contains a radiation activated catalyst that causes a phase change from liquid to solid in the material. A further embodiment combines a hot melt casting compound with a compound which contains a radiation activated catalyst that causes a phase change from liquid to solid in the material and a foaming or blowing agent.

Abstract: In one aspect, the present invention relates to a method of joining wax patterns for fabricating a golf club head. In one embodiment, the method has the step of providing a prefabricated first wax pattern and a prefabricated second wax pattern, embedding a joining portion of the second wax pattern into a recess portion of the first wax pattern, heating a flange formed on the recess portion to make the flange soften, and using a flattening tool to fold the flange over and into a chambered receiving portion on the second wax pattern such that the first wax pattern and second wax pattern are melted into a whole, joined surfaces of the first wax pattern and the second wax pattern are joined tightly with no gaps, and a single wax pattern if formed.

Abstract: A method for casting a cooled component includes molding a sacrificial pattern. A plurality of holes are formed through the pattern. A shell is formed over the pattern including filling the holes. The pattern is destructively removed from the shell. A metallic material is cast in the shell. The shell is destructively removed.

Abstract: Lost foam pattern assemblies formed by gluing together a plurality of EPS foam pattern segments with a polystyrene-like glue comprising an aromatic resin that has a molecular weight less than 10,000 and thermally degrades at temperatures no greater than said EPS. The glue contains sufficient first plasticizer, miscible with the resin, to impart a viscosity of about 0.1 to 5 PaS @ about 100-135° C. to the glue. The glue may optionally include a second, limited-miscibility, plasticizer to accelerate the hardening rate and increase the ultimate rigidity of the glue.

Abstract: A combing method of wax patterns for fabricating a golf club head is provided in the present invention. Firstly, a golf club head is disassembled to two or more elements in advance, which are respectively formed into wax patterns. Next, a flange capable of being deformed upon being pressed under an appropriate temperature and a corresponding rabbet structure are predisposed on the two wax patterns, then, the temperature of the flange is raised to make it soften, and then, it is pressed into the rabbet by a flattening tool. By utilizing the softening characteristic of the wax upon being heated, the joint surfaces of the two wax patterns are melted into a single wax pattern. By the method, the two wax patterns are combined together without adding a medium there-between, and thereby forming a joint surface with no gaps.

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.