Abstract: A casting mould comprising: an inorganic or refractory mould, wherein the mould is configured to receive feedstock; wherein the feedstock is configured to be heated in situ. A reusable mould, reusable susceptor, and/or release agent may be incorporated. Method of manufacturing a mould, and casting a part employing 5 in situ heating, are also provided.

Abstract: Various methods and systems are provided for manufacturing a radiation shielding component of an imaging apparatus. In one embodiment, the radiation shielding component may be manufactured by infiltrating metal particles with a binder solution and then curing the binder solution impregnated with the metal particles. In another embodiment, the radiation shielding component may be printed with metal powder, infiltrated with a binding agent, and then cured to polymerize the binding agent.

Abstract: An investment casting process for manufacturing a cast component is provided. The investment casting process includes forming a core, casting the cast component about the core such that a core positioning feature provides a location of an anticipated pilot hole in the cast component, removing the core from the cast component once the casting is completed, locating, forming and sizing a pilot hole to form a resized pilot hole that can receive a sealing plug and installing the sealing plug into the resized pilot hole.

Abstract: A cast component having reduced cross flow linking cavities and method of casting may include a body. The body may define a plurality of internal flow channels. The plurality of internal flow channels may include a first internal flow channel and a second internal flow channel. The cast component may also include a plurality of linking cavities obstructing unintended fluid communication between the first internal flow channel and the second internal flow channel through the plurality of linking cavities.

Abstract: A leachable casting core and method of manufacture may include a plurality of legs configured to establish a plurality of internal flow channels of a cast component. Tie bars, with a first tie bar end and a second tie bar end opposite thereof, may couple to at least two of the plurality of legs. At least one of the tie bars may be oriented to form a linking cavity within the cast component between the internal flow channels. The linking cavity may serve as an obstruction to fluid communication through the linking cavity.

Abstract: Partial integrated core-shell investment casting molds that can be assembled into complete molds are provided herein. Each section of the partial mold may contain both a portion of a core and portion of a shell. Each section can then be assembled into a mold for casting of a metal part. The partial integrated core-shell investment casting molds and the complete molds may be provided with filament structures corresponding to cooling hole patterns on the surface of the turbine blade or the stator vane, which provides a leaching pathway for the core portion after metal casting. Core filaments that can be used to supplement the leaching pathway, for example in a core tip portion of the mold are also provided herein.

Abstract: Integrated core-shell investment casting molds include a filament structure corresponding to a cooling hole pattern in the surface of the turbine blade, stator vane, or shroud.

Abstract: Integrated core-shell investment casting molds include a filament structure corresponding to a cooling hole pattern in the surface of the turbine blade, stator vane, or shroud.

Abstract: An airfoil includes an airfoil section that has an airfoil wall that surrounds a cavity. The airfoil wall includes a first wall section comprised of a monolithic ceramic shell, a second wall section comprised of a CMC liner that is bonded along an interface to an interior side of the monolithic ceramic shell, and a ceramic barrier coating that is bonded to an exterior side of the monolithic ceramic shell. The airfoil wall includes at least one of: inter-section cooling channels that extend along the interface and are bounded by the monolithic ceramic shell and the CMC liner, or intra-section cooling channels that extend within the CMC liner.

Abstract: A self-bonding refractory powder product for use in making a slurry for investment casting molds comprising a coarse refractory powder; a Nano-sized powder; and an organic polymer powder, wherein it does not require aqueous colloidal silica to produce slurries used to build investment casting molds. The Nano-sized powder comprises fumed alumina, boehmite, fumed silica, or fumed titanium oxide or combinations thereof. The coarse refractory powder comprises milled zircon, tabular alumina or fused alumina, fused silica, alumino-silicate, zirconia, and yttria or combinations thereof. The organic polymer powder comprises a cellulose-based material.

Abstract: This support member for additive manufacturing is a support to be disposed below a manufactured portion of a particular overhanging portion of the three-dimensional object which needs the support in the process of additively manufacturing the three-dimensional object. The support member is provided with: the support main body; and a polishing channel which is formed in the support main body so as not to be exposed to an interface with the three-dimensional object, and through which a polisher for polishing and removing the support main body is allowed to pass.

Abstract: An investment casting core system includes first and second investment casting cores. The first investment casting core has a pin and the second investment casting core has a hole and an access slot that opens to the hole. The pin is disposed in the hole such as to space the first investment casting core in a fixed position relative to the second investment casting core. A bonding agent is disposed in the access slot and around the pin in the hole.

Abstract: A blade outer air seal according to an exemplary aspect of the present disclosure includes, among other things, a body to be distributed circumferentially about a blade array. The body has a plurality of grooves, which can, for example, improve the aerodynamic efficiency of a turbine. A fin is between a first groove and a second groove of the plurality of grooves. The fin extends radially from the body and terminates at a radially inner fin face that provides one or more cooling outlets. A sacrificial structure for forming internal cooling passages within a blade outer air seal and a method of cooling an interface between a blade outer air seal and a rotating blade array is also disclosed.

Abstract: A fabrication method for fabricating a pattern for lost pattern casting, comprising at least one insert (10), providing at least two pattern portions (12, 14), said at least two portions being made of a material that can be eliminated, and assembling said at least two pattern portions together around at least a portion of said at least one insert in sealed manner so as to make said pattern (16).

Abstract: A self-bonding refractory powder product for use in making a slurry for investment casting molds comprising a coarse refractory powder; a Nano-sized powder; and an organic polymer powder, wherein it does not require aqueous colloidal silica to produce slurries used to build investment casting molds. The Nano-sized powder comprises fumed alumina, boehmite, fumed silica, or fumed titanium oxide or combinations thereof. The coarse refractory powder comprises milled zircon, tabular alumina or fused alumina, fused silica, alumino-silicate, zirconia, and yttria or combinations thereof. The organic polymer powder comprises a cellulose-based material.

Abstract: A nozzle guide vane for a gas turbine engine includes an integrally formed angled nozzle with radially outer and inner platforms and an airfoil extending therebetween. An internal cooling air passage extends between the platforms. A cooling air outlet in the inner platform communicates with the air passage and opens to an inter stage cavity between stages of the engine and is formed as part of the nozzle with an outlet axis angled with respect to a radial direction of the engine. A transition area between a radially outwards facing part of the nozzle and an approximately linear outlet part including the outlet axis is formed as a curved conduit bend. An investment casting core member includes a cone-shaped part that defines the bend, a support part attached to the cone-shaped part and a cylindrical part which extends to the surface of the inner platform.

Abstract: A method for designing a baffle including using patterns to produce an array of shell moulds, generating a 3-D image of the outer surface of each shell mould in the array of shell moulds, stacking the individual 3-D images for a plurality of the shell moulds to produce a conglomerate shell mould profile, determining a maximum cross sectional area of the conglomerate shell mould profile in a plane orthogonal to a direction along which the shell moulds are to be drawn through the baffle, defining a baffle profile segment which is consistent with a substantial portion of the conglomerate shell mould profile at the maximum cross sectional area, scaling the baffle profile segment to provide an offset clearance between the baffle profile segment and the maximum cross sectional area of the conglomerate shell mould profile, and reproducing the baffle profile segment to provide an array of baffle profile segments.

Abstract: A casting method for obtaining a part that includes a tapering portion, and a turbine engine blade obtained by casting and including a tapering trailing edge, are provided. The method includes: providing an insert element having a tapering section; making a shell around the insert element; and casting a molten material into the shell including the insert element.

Abstract: A turbine vane for a gas turbine engine has an inner platform, an outer platform, at least one airfoil extending between the inner and outer platforms, and a tab radially extending inward from a front side of the inner platform. The tab contains a mounting aperture and an identification aperture that identifies an engine in which the turbine vane may be installed.

Abstract: A casting, mold and method for producing a casting are disclosed. The casting may have an area of small thermal mass and an area of large thermal mass. The method includes providing a casting having a work product and an appendage engaged to, and suspended over, the work product between the area of small thermal mass and the area of large thermal mass, and controllably cooling the work product using the appendage.

Abstract: A method of casting a component (42) having convoluted interior passageways (44). A desired three dimensional structure corresponding to a later-formed metal alloy component is formed by stacking a plurality of sheets (18, 20) of a fugitive material. The sheets contain void areas (22) corresponding to a desired interior passageway in the metal alloy component. A ceramic slurry material is cast into the three dimensional structure to form either a ceramic core (34) or a complete ceramic casting vessel (38). If just a ceramic core is formed, a wax pattern is formed around the ceramic core and an exterior ceramic shell (38) is formed around the wax pattern by a dipping process prior to the removal of the fugitive material and wax. An alloy component having the desired interior passageway is cast into the casting vessel after the fugitive material is removed.

Abstract: A method of casting a component (42) having convoluted interior passageways (44). A desired three dimensional structure corresponding to a later-formed metal alloy component is formed by stacking a plurality of sheets (18, 20) of a fugitive material. The sheets contain void areas (22) corresponding to a desired interior passageway in the metal alloy component. A ceramic slurry material is cast into the three dimensional structure to form either a ceramic core (34) or a complete ceramic casting vessel (38). If just a ceramic core is formed, a wax pattern is formed around the ceramic core and an exterior ceramic shell (38) is formed around the wax pattern by a dipping process prior to the removal of the fugitive material and wax. An alloy component having the desired interior passageway is cast into the casting vessel after the fugitive material is removed.

Abstract: A method of casting a component (42) having convoluted interior passageways (44). A desired three dimensional structure corresponding to a later-formed metal alloy component is formed by stacking a plurality of sheets (18, 20) of a fugitive material. The sheets contain void areas (22) corresponding to a desired interior passageway in the metal alloy component. A ceramic slurry material is cast into the three dimensional structure to form either a ceramic core (34) or a complete ceramic casting vessel (38). If just a ceramic core is formed, a wax pattern is formed around the ceramic core and an exterior ceramic shell (38) is formed around the wax pattern by a dipping process prior to the removal of the fugitive material and wax. An alloy component having the desired interior passageway is cast into the casting vessel after the fugitive material is removed.

Abstract: A system for producing cast components from molten metal. One form of the present invention includes a system for the precision pouring of molten metal within a casting mold.

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 rapid manufacturing method includes forming tooling in a rapid manufacturing process. The tooling is coated with a conductive material.

Abstract: A turbine airfoil usable in a turbine engine and including a depth indicator for determining outer wall blade thickness. The airfoil may include an outer wall having a plurality of grooves in the outer surface of the outer wall. The grooves may have a depth that represents a desired outer surface and wall thickness of the outer wall. The material forming an outer surface of the outer wall may be removed to be flush with an innermost point in each groove, thereby reducing the wall thickness and increasing efficiency. The plurality of grooves may be positioned in a radially outer region of the airfoil proximate to the tip.

Abstract: A method of manufacture of a wax model of an annular bladed turbomachine stator assembly includes in succession the positioning, in a mold, of a core intended to form the impression of a cavity of a blade of the assembly, the injection of a wax in the mold, and the removal of the wax model fitted with the core from the mold. The core is manufactured in metal and is positioned such that its radially internal end is housed in the portion of the mold defining the blade including the cavity, away from the radially internal end of this portion of the mold.

Abstract: A core for creating an airfoil has a ceramic material that forms a body. The body has an outer dimension, a slot extending through the outer dimension and into the body for receiving an insert, the slot disposed at an angle to the outer dimension, and a trip strip having a first portion disposed in the outer dimension. The first portion is in register with the slot wherein a constant dimension such as minimum thickness is maintained between the trip strip and the slot along a length of the slot and wherein said first portion tapers towards said outer dimension.

Abstract: A method involves forming a core assembly. The forming includes deforming a wire, the deforming including increasing a transverse linear dimension along at least one portion of the wire. The wire is assembled to a ceramic core.

Abstract: A turbine engine airfoil includes an airfoil structure having an exterior surface providing a leading edge. A radially extending first cooling passage is arranged near the leading edge and includes first and second portions. The first portion extends to the exterior surface and forms a radially extending trench in the leading edge. The second portion is in fluid communication with a second cooling passage. In one example, the second cooling passage extends radially, and the first cooling passage wraps around a portion of the second cooling passage from a pressure side to a suction side between the second cooling passage and the exterior surface. In the example, the first portion is arranged between the pressure and suction sides. In one example, the first cooling passage is formed by arranging a core in an airfoil mold. The trench is formed by the core in one example.

Abstract: A cast metal article is formed with an internal cavity. The internal cavity is formed by a ceramic core which is removed from the cast metal article to leave the cavity. The ceramic core is formed with a cavity to facilitate removal of the core from the cast metal article. To remove the core from the cast metal article, the cavity in the core is filled with a leaching liquid.

Abstract: A hybrid core assembly for a casting process includes a ceramic core portion, a first refractory metal core portion and a first plate positioned between the ceramic core portion and the first refractory metal core portion. The ceramic core portion includes a first trough. A portion of the refractory metal core portion is received in the first trough.

Abstract: A hybrid core assembly for a casting process includes a ceramic core portion and a refractory metal core portion that interfaces with a ceramic core trough of the ceramic core portion. The refractory metal core portion includes a finger having a bent portion that establishes a refractory metal core trough aligned with the ceramic core trough.

Abstract: A process for casting a turbine engine component is provided. The process comprises the steps of placing a refractory metal core assembly comprising two intersecting plates in a die, encapsulating the refractory metal 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 casting core assembly includes a metallic core and a ceramic core. The process for forming the casting core assembly includes inserting a ceramic plug of a metallic core and ceramic plug core subassembly into a compartment of the ceramic core. The ceramic plug is secured to the ceramic core.

Abstract: A method of forming a cast component includes at least partially surrounding an investment mold in a heat-insulating packing material, feeding a molten alloy into the investment mold to provide a filled investment mold, and agitating the filled investment mold while solidifying the molten alloy.

Abstract: An insulated investment casting shell mold is made by first mixing at least one refractory material with a slurry vehicle forming a prime coat slurry, and optionally mixing at least one refractory material with a slurry vehicle forming a backup slurry. The prime slurry is coated onto a fugitive pattern and optionally dried and/or stuccoed wherein the stucco has at least one refractory material. Optionally, at least one coat of the backup slurry is applied to the prime coated fugitive pattern and optionally dried and/or stuccoed after each coat of the backup slurry. The backup and stucco may be applied a plurality of times to obtain a desired shell wall thickness. An insulating slurry is formed by introducing gas into a slurry vehicle having at least one refractory material and containing a stabilizer and a foaming agent wherein gaseous bubbles become entrained therein forming an insulating slurry having closed porosity therein.

Abstract: A sprue for use in investment casting may comprise a pin and a shell enclosing a part of the pin. A method for creating a sprue may comprise partially enclosing a pin in a shell.

Abstract: A casting process and apparatus for producing directionally-solidified castings, and castings produced therewith. The process entails applying a facecoat slurry to a surface within a mold cavity to form a continuous solid facecoat on the surface, introducing a molten metal alloy into the mold cavity so that the molten metal alloy contacts the facecoat, and then immersing the mold in a liquid coolant to cool and solidify the molten metal alloy and form a casting of the metal alloy, during which an oxide layer forms on the casting surface. The facecoat is sufficiently adherent to the oxide layer such that at least a portion of the facecoat detaches from the mold surface and remains tightly adhered to the casting surface in the event the casting contracts during cooling. The facecoat contains at least 60 weight percent of a first phase of yttria, and the balance of the facecoat is a binder phase of an inorganic material.

Abstract: A core-in-a-core casting method and hybrid core (40) for use in the method. An inner core (42) formed of process-inert particles disposed in a binder material is used as a mold for casting an outer core ((44) formed of particles that will sinter during a subsequent firing step. The inner core provides mechanical support for the outer core during the firing step, and during which the inner core devolves into compacted but unbonded particles that can be removed conveniently from the outer core following the firing step to reveal the fired hollow outer core (44).

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: A cast turbine blade is disclosed and includes an internal cooling passage that passes (e.g., zig-zags or meanders) through the blade from an inlet in the blade root to an outlet in the blade tip. The cooling passage can have a zone at a bend that is at a distance which is remote from the inlet of the cooling passage when the distance from the inlet is measured around the passage, but that is closer to the inlet when the distance from the inlet is measured in a straight line. During casting of the blade, the cooling passage can be defined by a core or cores having a leachable material, the cores being removed after casting by a chemical leaching process. A supplementary passage is also provided for connecting the remote zone to the inlet during the leaching process. The supplementary passage can likewise be defined by a leachable core, or it may be machined into the blade after casting.

Abstract: A slurry suitable for forming facecoats, facecoats formed by such a slurry, and processes using such facecoats. The slurry is formed of a particulate refractory material, an aqueous suspension containing a particulate inorganic binder, a thixotropic organic binder, a dispersant, and possibly optional constituents excluding particulate refractory materials and inorganic binders. The particulate refractory material constitutes at least about 60 weight percent of the slurry and consists essentially of yttria. The aqueous suspension containing the particulate inorganic binder constitutes at most about 35 weight percent of the facecoat slurry. The dispersant is present in the slurry in an amount sufficient to stabilize the slurry at a pH of up to about 10, and has the general formula Hx[N(CH2)yOH]z, where x has a value of 0, 1 or 2, y has a value of 1 to 8, and z=3?x.

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. A mating edge portion of the metallic casting core includes a number of projections. The first region is along at least some of the projections. A number of recesses span gaps between adjacent projections. The ceramic feedcore includes a number of compartments respectively receiving the metallic casting core projections. The ceramic feedcore further includes a number of portions between the compartments and respectively received in the metallic casting core recesses.

Abstract: In precision casting of metallic components with very thin passage ducts, in particular turbine blades, by the lost-wax process, the ceramic core pins provided for forming the passage ducts are covered and stabilized via a low-melting reinforcing coat prior to injection of the wax material required for forming the wax pattern for the production of the ceramic casting mold, with the low-melting reinforcing coat being melted out together with the wax material after the casting mold has been formed on. The ceramic core pins are therefore not damaged during the production of the wax pattern, enabling very thin passage ducts to be formed in the precision casting process.

Abstract: Investment casting shells are manufactured by incorporating fumed metal oxide dispersions, or doped fumed metal oxides as a binder into the casting shell. The investment casting shells containing the fumed metal oxides have improved characteristics, such as increased strength and a reduced surface roughness.

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: 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.