Abstract: A core molding method is a method of molding a core using a metal mold that is pressure-fed with mulled sand, and includes heating the metal mold such that the temperature of the metal mold reaches a temperature higher than a predetermined baking temperature, pressure-feeding the heated metal mold with the mulled sand, holding the temperature of the metal mold having been pressure-fed with the mulled sand at the baking temperature, and removing the core from the metal mold after the holding.

Abstract: A method for manufacturing an aluminium mould (1) segment (10) for curing and vulcanizing a tyre comprises: a) fixing at least one thin blade (2) for the formation of the grooves in the tire tread, in a mould form made of friable material, so that an exterior part of the thin blade is embedded in the material of the mould form and so that an interior part projects from this mould form, this thin blade being made from maraging steel and having been obtained by a selective laser melting method, b) closing the mould form and pouring or injecting aluminium into it, coating the interior part of the thin blade, c) breaking away the mould form to obtain the mould segment. The thin blade (2) is subjected to a peening treatment with a material with a Vickers hardness between 340 and 500 HV and with dimensions smaller than 0.3 mm.

Abstract: The sand mould identification device has a housing with an identification pattern face adapted to be arranged in a pattern forming surface of a sand moulding machine. Individually adjustable indicator elements in the identification pattern face are adjustable by means of an actuator. The housing includes an insertion portion adapted to be inserted into a corresponding recess of said sand moulding machine. The identification pattern face is located at a front end of the insertion portion. The insertion portion is adapted to be inserted into the sand moulding machine in an insertion direction extending from a rear end to the front end of the insertion portion. A mounting bracket is accessible at or behind the rear end of the insertion portion for mounting or demounting the housing to or from the sand moulding machine or core shooter.

Abstract: A core element of an investment core for use in a casting process used to produce an airfoil includes an investment core body, an extension connected to and protruding from the investment core body, and a connection portion connected to the investment core body and to the extension. The investment core body includes a ceramic material. A shape of the extension includes a tube with a centerline axis passing through a center of the extension. A shape of a cross-section of the extension taken along a plane perpendicular to the extension centerline axis includes an ellipse. The extension is connected to the investment core body by the connection portion.

Abstract: A method of treating a surface of a mold. A preliminary treatment of dry-ejecting an angular carbide powder against the surface of the mold so as to cause elemental carbon present within the carbide powder to be diffused into the surface of the mold. The carbide powder has particle diameters not larger than those of a 220 grit and the carbide powder being dry-ejected at an ejection pressure of 0.2 MPa or greater. An after-treatment of dry-ejecting a spherical powder against the surface of the mold to cause the spherical powder to impact the surface of the mold and form innumerable circular arc shaped fine depressions. The spherical powder has a hardness not less than the hardness of a base material of metal of the mold and particle diameters not larger than those of a 220 grit and dry-ejected at an ejection pressure of 0.2 MPa or greater.

Abstract: A turbine blade has an attachment root and an airfoil. A cooling passageway system has a plurality of trunks extending from respective inlets along the root inner diameter end from a leading trunk near a first axial end to a trailing trunk near a second axial end; and a plurality of outlets along the airfoil including trailing edge outlets fed by the trailing trunk. Viewed normal to a root end-to-end centerplane: the trailing trunk has a turn passing forward and then rearward; an outside of the turn protrudes forward; and the outside of the turn has a tighter curvature than an inside of the turn.

Abstract: A method for producing a model mould core blank uses a ceramic blank fixed to a processing holder. During fixing, a lost core is manufactured from the ceramic blank based on a CNC manufacturing process 3D model, the processing holder being fastened in the running CNC machine. A model blank is produced by casting model material around the lost core while fixing persists. The model blank becomes part of another method for producing a model mould core, wherein an outer contour of a lost model is produced from and/or on the model blank on the basis of a second CNC manufacturing process 3D model, wherein fixing and processing holder fastening also occurs. Another method produces a precision casting mould, in which a ceramic mould is applied to the outer contour of the lost model, and a cast part having a hollow cavity structure is produced by the precision casting mould.

Abstract: A molding tool made of carbon or graphite, namely a casting mold or a casting core for the processing of molten metal or to a molding tool for the processing of molten glass, such as for example a blow mold and a method for producing the molding tool.

Abstract: Provided are: a mold material having improved fluidity and being capable of improving a filling rate of a forming mold during formation of a casting mold; and a mold material that gives cast products a favorable casting surface, effectively improves sand adhesion on cast products, and advantageously provides a casting mold having excellent strength. The mold material is formed as a coated sand in a wet state with spherical particles of silicone resin having binder repellency existing on its surface, by at least mixing a water-soluble inorganic binder in the liquid state having a viscosity of not more than 1000 cP, and the spherical particles of silicone resin, with a refractory aggregate.

Abstract: Compositions useful for foundry processes such as green sandcasting are discussed. The compositions may include ball clay, bentonite, and a carbonaceous material. The ball clay may include leonardite and/or causticized lignite, e.g., as a portion of the natural ball clay deposit. The composition may further include sand, such that the resulting mixture may be formed into a green sand mold for use in casting molded articles. Incorporation of ball clay materials in the compositions may help to improve the quality of the casted article.

Abstract: A blade outer air seal segment including a radially outward surface, a radially inward surface oriented away from the radially outward surface, and a cooling channel located between the radially outward surface and the radially inward surface. The blade outer air seal segment also including a stress-relief boss extending into the cooling channel and an inlet orifice fluidly coupled to the cooling channel through the stress-relief boss.

Abstract: A method including modifying a known upper denture to form a final upper denture by a series of steps which may include making holes in a gums section made of a first material of the known upper denture, cutting away a palate section, and applying a gold and silicon mixture to make a new palate section, to insert into the holes in the gums section, and to cover the first material. The method may also include modifying a known lower denture to form a final lower denture by a series of steps which may include making holes in a gums section made of a first material of the known lower denture, and applying a gold and silicon mixture to insert into the holes, and to cover the first material. The first material may be nylon.

Abstract: A surface treatment method is provided that is capable of raising the slidability of a ceramic surface at low cost using a comparatively simple method. Dimples are formed on a surface of a treatment region, this being a portion of a ceramic surface where surface treatment is to be performed, by ejecting substantially spherical ejection particles having a median diameter of from 1 ?m to 20 ?m, together with compressed gas at an ejection pressure of from 0.01 MPa to 0.7 MPa, so as to achieve a value of a fastest decay autocorrelation length of not less than 10. The dimples are formed so as to have a plan view profile with a ratio between a horizontal Feret diameter and a vertical Feret diameter of from 0.7 to 1.43. Thereby a ceramic surface with improved slidability can be obtained regardless of use or non-use of a lubricant.

Abstract: A method of treating a surface of a mold. The method includes forming dimples on a surface of a mold by ejecting substantially spherical ejection-particles so as to bombard the surface of the mold. The dimples are formed so as to satisfy a condition defined by the following formula: 1+3.3e?H/230?W?3+13.4e?H/1060 wherein W is an equivalent diameter (?m) of the dimples and H is a base metal hardness (Hv) of the mold.

Abstract: A method for making internal passages for use in investment casting processes, especially for gas turbine components such as blades or vanes. The apparatus includes a first mold cavity having grooves formed therein, a second mold cavity having a shape complementary to the final casting design and ceramic cores. Each groove of the first mold cavity has a depth equal to a radius of a certain number of ceramic cores which correspond to cooling channels. The ceramic cores are placed in the first mold cavity and fugitive wax is injected for temporary positioning of the cores. Two fugitive wax segments are formed about the cores. The fugitive segments locate the ceramic cores in the second mold cavity, and wax is injected about the cores and locating segments to form a pattern for investment casting process.

Abstract: A method of casting a product includes the steps of: creating a finished photopolymer mold; introducing liquid into the mold; hardening the liquid; and removing the photopolymer mold. A casting mold and a method of making a casting mold, are also disclosed.

Abstract: A method for producing an aluminum alloy foam wherein an aluminum alloy, in molten form, infiltrates the interstices of a preform of silicon elastomer elements, by means of a conventional molding process, typically a low-pressure process, followed by the elimination of the preform broken down into silica powder during the molding cycle and/or an additional baking cycle.

Abstract: A mold for hot stamping is disclosed. The mold may include: a base plate configured to receive and exhaust coolant, at least one lower mold and at least one upper mold. The at least one lower mold may be mounted at a surface of the base plate, and configured to receive the coolant from the base plate. The lower mold may also have the same shape as a lower shape of a product so as to form the lower shape of the product during hot stamping. The upper mold is made of material different from that of the lower mold, coupled to an upper portion of the lower mold, has the same shape as an upper shape of the product so as to form the upper shape of the product, and is configured to receive the coolant from the lower mold such that the coolant flows in the upper mold.

Abstract: The invention relates to a turbomachine bearing support (1) supporting at least one bearing and extending according to a longitudinal principal axis of the turbomachine and comprising: a truncated part (11) having a diameter increasing from upstream to downstream; a flange part (12) which extends from the truncated part (11) as far as the bearing (5, 6) to which it is fixed by an axial flange (121), and having at its downstream end a radial internal flange (17) fixed to an oil inlet cover defining with the bearing (5, 6) an oil inlet container (170); oiled air clearance ducts (71) projecting downstream relative to the flange part (12) and on the oil inlet container (170) and to the other side upstream of the flange part (12) directly radially externally relative to the axial flange (121).

Abstract: Apparatus and method for continuously casting metal strip includes a pair of casting rolls having casting surfaces with a center portion, edge portions each having average surface roughness between 3 and 7 micrometers Ra, and intermediate portion between each edge portion and the center portion, the center portion average surface roughness between 1.2 and 4.0 times the edge portion surface roughness, and the intermediate portions average surface roughness between that of the edge and center portions. The surface roughness of the center portion is tapered across its width, and may be tapered across its width is in stepped zones. The center portion may have surface roughness varied across the surface to correspond to a desired variation in metal shell thickness across the cast strip. The center portion may be at least 60% of the casting roll width, and each edge portion may be up to 7% of the casting roll width.

Abstract: A railroad coupler assembly having at least a body and a knuckle both formed in a no-bake manufacturing process, the body and the knuckle having dimensional tolerances of distances between features that wear during operation that are about half those obtained from a body and a knuckle manufactured by a green sand process, resulting in increased fatigue life compared to the body and the knuckle manufactured by a green sand process.

Abstract: A method of using a bonded refractory mold is disclosed. The method includes forming a refractory mold including a mold wall on a fugitive pattern including a thermally removable material. The mold wall including a refractory material and defining a sprue, a gate and a mold cavity, the gate having a gate inlet opening into the sprue and a gate outlet opening into the mold cavity; a gas vent extending through the mold wall; and a gas permeable refractory material covering the gas vent, the fugitive pattern having a sprue portion, the sprue portion having a sprue channel that is in fluid communication with a sprue inlet and that extends toward a sprue outlet. The method also includes heating the refractory mold with a hot gas to remove the thermally removable material, wherein a portion of the hot gas is exhausted from the refractory mold through the gas vent.

Abstract: A method of making a bonded refractory mold is disclosed. The method includes forming a fugitive pattern including a thermally removable material. The method also includes forming a refractory mold including a mold wall, the mold wall including a refractory material and defining a sprue, a gate and a mold cavity, the gate having a gate inlet opening into the sprue and a gate outlet opening into the mold cavity, the mold defined by the fugitive pattern. The method further includes forming a gas vent that extends through the mold wall. The method also includes covering the gas vent with a gas permeable cover.

Abstract: Tweezers, in particular, cosmetic tweezers, include two legs extending in longitudinal direction. The two legs have connecting ends and free ends and are connected to one another at their connecting ends. The free ends form inner jaw surfaces shaped to hold an object therebetween. Both of the legs and the connecting area are of a metallic glass or of an amorphous metal in one piece.

Abstract: A holder block system suitable for producing metal castings. The holder block system includes a holder block primary mold that has one or more cavities that accept a sub-mold that incorporates the features of the part to be cast, wherein the sub-mold can be produced utilizing 3-D printing. Methods of preparing holder block patterns and cast objects are with the holder block system disclosed.

Abstract: A mold in which a fine uneven structure is formed on the surface by anodizing a surface of an aluminum base material having a purity of equal to or more than 99.5% by mass, wherein a 60-degree gloss of the surface on the side where a fine uneven structure is formed is equal to or more than 750%.

Abstract: A method is provided for making a mold for casting advanced turbine airfoils (e.g. gas turbine blade and vane castings) which can include complex internal and external air cooling features to improve efficiency of airfoil cooling during operation in the gas turbine hot gas stream. The method steps involve incorporating at least one fugitive insert in a ceramic material in a manner to form a core and at least a portion of an integral, cooperating mold wall wherein the core defines an internal cooling feature to be imparted to the cast airfoil and the at least portion of the mold wall has an inner surface that defines an external cooling feature to be imparted to the cast airfoil, selectively removing the fugitive insert, and incorporating the core and the at least portion of the integral, cooperating mold wall in a mold for receiving molten metal or alloy cast in the mold.

Abstract: A method of using a bonded refractory mold is disclosed. The method includes forming a refractory mold comprising a mold wall on a fugitive pattern comprising a thermally removable material, the mold wall comprising a refractory material and defining a sprue, a gate and a mold cavity, the gate having a gate inlet opening into the sprue and a gate outlet opening into the mold cavity; a gas vent extending through the mold wall; and a gas permeable refractory material covering the gas vent, the fugitive pattern having a sprue portion, the sprue portion having a sprue channel that is in fluid communication with a sprue inlet and that extends toward a sprue outlet. The method also includes heating the refractory mold with a hot gas to remove the thermally removable material, wherein a portion of the hot gas is exhausted from the refractory mold through the gas vent.

Abstract: A method of making a bonded refractory mold is disclosed. The method includes forming a fugitive pattern comprising a thermally removable material. The method also includes forming a refractory mold comprising a mold wall, the mold wall comprising a refractory material and defining a sprue, a gate and a mold cavity, the gate having a gate inlet opening into the sprue and a gate outlet opening into the mold cavity, the mold defined by the fugitive pattern. The method further includes forming a gas vent that extends through the mold wall. The method also includes covering the gas vent with a gas permeable cover.

Abstract: A method for manufacturing a stent includes forming a stent blank from a first material, the stent blank comprising a plurality of struts and a plurality of crowns, each crown connecting at least two struts, and a plurality of slots in at least some of the plurality of struts and/or the plurality of crowns, depositing a second material over outer surfaces of the struts and the crowns and in the slots to encase the stent blank in the second material, creating at least one opening through the second material, and removing the first material to form a stent comprising the second material, the stent having a continuous lumen from one end of the stent to the other end of the stent, the continuous lumen being partitioned in portions corresponding to the locations of the slots in the stent blank. The lumen may then be filled with a therapeutic substance.

Abstract: A method of forming a nanostructured surface, including providing an original nanostructured surface having an array of high aspect ratio structures formed on a planar substrate; forming a negative replica mold of the original nanostructured surface, where the negative replica mold includes a flexible material; deforming the negative replica mold; and using the deformed negative replica mold to form a deformed replica of the original nanostructured surface, where the deforming step is performed at least one of before, during, or after introducing a material for forming the deformed replica into the negative replica mold.

Abstract: A method for making hollow metal tubes includes a step combining a polyphenylene sulfide-containing resin with a water soluble carrier resin to form a resinous mixture. The resinous mixture is then extruded to form an extruded resinous mixture. The extruded resinous mixture includes polyphenylene sulfide-containing fibers within the carrier resin. The extruded resinous mixture is contacted (i.e., washed) with water to separate the polyphenylene sulfide-containing fibers from the carrier resin. The polyphenylene sulfide-containing fibers are then coated with a metal layer. The hollow metal tubes are then formed by removing the polyphenylene sulfide-containing fibers.

Abstract: The present invention relates to the fabrication of complicated electronic and/or mechanical structures and devices and components using homogeneous or heterogeneous 3D additive build processes. In particular the invention relates to selective metallization processes including electroless and/or electrolytic metallization.

Abstract: A molding apparatus is provided. The molding apparatus includes a first block configured to receive a moldable article therein, a second block positioned a distance from the first block, and a shim including graphite. The shim is positioned between the first block and the second block, wherein the shim gradually disintegrates when heated such that the second block contacts the first block.

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 manufacturing a porous metal foam having pores of nano size includes: manufacturing a porous polymer foam containing pores of nano size; and coating metal on the porous polymer foam through electroless plating. The present invention provides porous metal foams which contains nano-sized pores and hence, their specific surface area is maximized owing to the regularly-patterned nanoporous structure formed inside.

Abstract: A mold assembly for forming a cast component includes a primary mold structure having a predetermined geometry portion for shaping a primary region of the cast component. Also included is at least one additional mold structure integrated with the primary mold structure, the at least one additional mold structure comprising a geometry for defining at least one feature in the cast component.

Abstract: Metal alloy injection molding techniques are described. In one or more implementations, these techniques may also include adjustment of injection pressure, configuration of runners, and/or use of vacuum pressure, and so on to encourage flow of the metal alloy through a mold. Techniques are also described that utilize protrusions to counteract thermal expansion and subsequent contraction of the metal alloy upon cooling. Further, techniques are described in which a radius of edges of a feature is configured to encourage flow and reduce voids. A variety of other techniques are also described herein.

Abstract: The present disclosure provides a multi-layer tool piece coating. For example, the tool piece may be a mold or die used for forming ultra high strength steel sheet. The multi-layer mold coating may include a CrN or Ti(C)N junction layer, a first TiAlN/CrN nano multilayer, and a second TiAlCN/CrCN nano multilayer. The CrN or Ti(C)N junction layer may be coated on a base material of the tool piece (e.g., a mold) for forming the steel sheet. The first TiAlN/CrN nano multilayer may be coated on the CrN or Ti(C)N junction layer as an intermediate layer. The second TiAlCN/CrCN nano multilayer may be coated on the first TiAlN/CrN nano multilayer as an outermost surface functional layer, and may include carbon (C) of about 1 at. % to about 30 at. % for high temperature and low friction.

Abstract: A component casting apparatus includes a mold to receive a molten solid for casting a component. The mold includes a first sacrificial layer to define a housing of the component and a second sacrificial layer to form at least one core passage of the component in response to contact from the molten solid. The component casting apparatus further includes a trusset disposed against an outer surface of the second sacrificial layer and formed from metal to support the second sacrificial layer.

Abstract: Metal alloy injection molding techniques are described. In one or more implementations, these techniques may also include adjustment of injection pressure, configuration of runners, and/or use of vacuum pressure, and so on to encourage flow of the metal alloy through a mold. Techniques are also described that utilize protrusions to counteract thermal expansion and subsequent contraction of the metal alloy upon cooling. Further, techniques are described in which a radius of edges of a feature is configured to encourage flow and reduce voids. A variety of other techniques are also described herein.

Abstract: A method of producing an integral self supporting coating test piece from particulate material including the steps of (i) producing a reusable mould having a depression which conforms to the desired shape and volume of said coating test piece, the reusable mould including silicone rubber, (ii) roughening the surface of the reusable mould, (iii) heat treating the reusable mould, (iv) thermally spraying particulate material into the depression in the reusable, mould, and (v) removing the reusable mould from the solidified coating test piece.

Abstract: Provided herein are various embodiments of systems for casting thin metal plates and sheets. Typical embodiments include layers of mold cavities that are oriented vertically for casting the metal plates. In some embodiments, the mold cavities include a beveled edge such that the plates that are cast have a beveled edge. In some embodiments, the mold cavities are filled with a molten metal through an open horizontal edge of the cavity. In some embodiments, the mold cavities are filled through one or more vertical feed orifices. Further disclosed are methods for forming a thin cast metal plate or sheet where the thickness of the cast part is in a range from 0.005 inches to 0.2 inches, and the surface area of the cast part is in a range from 16 square inches to 144 square inches.

Abstract: Metal alloy injection molding techniques are described. In one or more implementations, these techniques may also include adjustment of injection pressure, configuration of runners, and/or use of vacuum pressure, and so on to encourage flow of the metal alloy through a mold. Techniques are also described that utilize protrusions to counteract thermal expansion and subsequent contraction of the metal alloy upon cooling. Further, techniques are described in which a radius of edges of a feature is configured to encourage flow and reduce voids. A variety of other techniques are also described herein.

Abstract: A method for manufacturing a metallic component especially configured and designed for a turbomachine includes a) for a precision-casting process, a wax model with a wax structure is produced, subsequently b) the tip of the wax structure is thermally and/or mechanically treated such that a region with an undercut is formed on the wax structure, subsequently c) the metallic component is manufactured from the wax model in the precision-casting process, with a component structural element with an undercut forming on a surface of the component, and d) the component structural element is provided at least partially with a ceramic coating, a plastic-containing coating, in particular a fibre composite layer and/or a plastic component.

Abstract: A casting core assembly includes a metallic core and a ceramic core. A protuberant portion of a metallic core is received in a compartment of the ceramic core.

Abstract: A method of manufacturing a friction wedge of a rail car includes forming, in drag and cope portions of a mold, at least one cavity that defines at least some exterior features of at least one friction wedge. At least one core is inserted into the drag portion adjacent to the cavity. The core includes at least one surface configured to define a column face of the friction wedge. Rigging is formed in the drag and cope portion of the mold. The rigging includes a down sprue, at least one ingate, and at least one runner for directing molten material to the cavity. Molten material is poured into the mold to form the friction wedge casting. The friction wedge casting is removed from the mold. Rigging is removed from the friction wedge casting and the friction wedge casting is finished.

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 may comprise 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 core assembly for forming a cast component includes a refractory metal core and a ceramic core element. The refractory metal core includes first and second ends and sides extending from the first end to the second end. The ceramic core element includes a slot positioned between first and second lands, each land having an inner surface facing the slot and an adjacent outer surface. The first end of the refractory metal core is secured within the slot with an adhesive, and the refractory metal core extends from the ceramic core element in both a longitudinal and a transverse direction. The slot, lands, and refractory metal core form a core assembly providing access paths to the sides of the refractory metal core. Surplus adhesive is removed from the refractory metal core via the access paths. Investment casting provides the component with an internal passage and an internal cooling circuit.

Abstract: A blade for a gas turbine has a leading edge and a trailing edge, and an interior cavity, which is delimited by internal surfaces, for guiding cooling air therethrough. A multiplicity of turbulators or pins, which are formed on the wall, are arranged in a distributed manner in the region of the trailing edge and project from the internal surfaces into the cavity, to improve the transfer of heat between the wall of the blade and the cooling air. An improvement of the internal cooling is achieved by the turbulators or pins extending into the cavity in a direction which can be freely selected within an angular range.