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 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.

Abstract: Disclosed is a method of manufacturing an impeller or a turbine wheel having a disk hub and an air foil. The method includes forming a mold for casting including a cavity of a shape corresponding to the rotor, arranging a core at a location corresponding to an inside of the rotor in the cavity of the mold for casting, injecting molten metal into the mold for casting where the core has been arranged, and removing the core from a casting which has been cast in the mold for casting.

Abstract: An airfoil includes leading and trailing edges; first and second sides extending from the leading edge to the trailing edge, each side having an exterior surface; a core passage located between the first and second sides and the leading and trailing edges; and a wall structure located between the core passage and the exterior surface of the first side. The wall structure includes a plurality of cooling fluid inlets communicating with the core passage for receiving cooling fluid from the core passage, a plurality of cooling fluid outlets on the exterior surface of the first side for expelling cooling fluid and forming a cooling film along the exterior surface of the first side, and a plurality of cooling passages communicating with the plurality of cooling fluid inlets and the plurality of cooling fluid outlets. At least a portion of one cooling passage extends between adjacent cooling fluid outlets.

Abstract: A hybrid sacrificial core for forming an impingement space and an internal cooling passageway network separate from the impingement space of a part may comprise a ceramic core having a first surface portion for forming the impingement space, and a refractory metal core that forms a plurality of passages of the internal cooling passageway network.

Abstract: An evaporative pattern casting method is taught which does not reduce accuracy of an evaporative pattern. The evaporative pattern casting method comprises a part manufacturing process (S2), an assembly process (S4), a sand mold manufacturing process (S6), a molten metal pouring process (S8) and a sand removal process (S12). In the part manufacturing process, the evaporative pattern is manufactured as a plurality of separate parts. In the assembly process, the parts are assembled on a work plane. In the sand mold manufacturing process, the evaporative pattern is covered with sand to form a sand mold without moving the assembled evaporative pattern from the work plane. In the molten metal pouring process, molten metal is poured into the sand mold. In the sand removal process, the sand is removed after the molten metal has solidified.

Abstract: A lightweight metal mold having a necessary rigidity is realized. Firstly, an original pattern of an evaporative pattern is formed by machining an evaporative material block. The original pattern includes a three-dimensional mesh structure including a plurality of bar-shaped parts and connecting points that connect ends of the bar-shaped parts and are distributed in a three-dimensional space, and a plurality of block parts having fixed relative positional relationship by being fixed to the three-dimensional mesh structure. Then, at least a portion of at least one or more of the bar-shaped parts composing the original pattern is removed, and replaced with a tube member. Then, a full-mold casting is performed by using the evaporative pattern having the replaced tube member. Positional relationship of the block parts in which surfaces, etc. necessary for the metal mold are formed is fixed by the three-dimensional mesh structure, and the necessary rigidity is secured.

Abstract: The invention relates to a rotary lobe pump for conveying a fluid medium containing solids, comprising an inlet and an outlet for the medium being conveyed, and further comprising a pump casing and two rotary lobes arranged in said pump casing and having intermeshing rotary lobe vanes. According to the invention, the pump casing has two opposite casing half-shells which seal the pump casing fluid-tightly. The casing half-shells are double-walled.

Abstract: A method of serializing a cast part includes providing a mold for a metal casting, with the mold including an inner face partially defining a part cavity; laser engraving a representation of the two-dimensional data matrix into the inner face of the mold; and forming a serialized part by pouring molten metal into the part cavity of the mold, where the molten metal fills the part cavity including the engraved representation of the two-dimensional data matrix. The two-dimensional data matrix being generated by an electronic controller and includes error correcting information and part identifying information.

Abstract: A method comprising the use of additive manufacturing techniques for creating molds and pattern parts for subsequent use in the casting of die components and die shoes for use in die stamping processes.

Abstract: A mold for casting in one piece of a tool with a working component of steel and a body of grey iron with an interconnection zone there between has a first model section corresponding to the working component and a second model section corresponding to the body. The model sections are in contact with one another along a contact plane which is horizontal and planar and which represents the interconnection zone. In a method for producing a mold for one piece casting of a tool with a working component of steel and a body of grey iron with an interconnection zone therebetween; a first model section is produced corresponding to the steel and a second model section corresponding to the grey iron. The model sections are brought into contact with one another with the contact surface horizontally aligned and with the first model section lowermost.

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 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 system includes a turbine blade, which includes at least one cooling slot configured to convey a coolant in a flow direction from an interior to an exterior of the turbine blade. The cooling slot includes an entrance coupled to the interior and a converging section downstream from the entrance. The converging section includes a first cross-sectional area that decreases in the flow direction. The cooling slot also includes an exit disposed along a trailing edge of the turbine blade.

Abstract: A casting assembly for manufacturing a lock of a railcar coupler includes drag and cope portions of a first mold that defines exterior surfaces of the lock, wherein the first mold comprises a first molding material. The casting assembly also includes a second mold formed of a second molding material. The second mold defines a cavity with an interior surface that substantially complements an exterior surface of the first mold. A down sprue is formed in the second mold. A gating system is formed in the second mold that and is in fluid communication with the down sprue. An in-gate is formed in the second mold and is in fluid communication with the gating system and the first mold.

Abstract: A crankshaft is cast in a mold to define a plurality of pin bearing journals and a plurality of main bearing journals, at least one of each has a hollow section extending therethrough. A single core is positioned within the mold to form all of the hollow sections. The single core may include a cross-section defining an elliptical shape to form hollow sections having an elliptical cross-sectional shape to further reduce the weight of the crankshaft. The hollow sections are each positioned along a path that minimizes stress within the crankshaft. The path may include a non-linear path relative to a longitudinal axis of the crankshaft or a linear path angled relative to the longitudinal axis to bend or direct the hollow sections away from high stress regions of the crankshaft. The non-circular cross section of the core may spiral about its own axis to maximize mass reduction.

Abstract: A method for producing a brake disc comprising a coupling part having a centered through-hole a friction part on the periphery of the coupling part, and a wall part connecting the coupling part and the friction part, including: producing a mold in which the coupling part, the wall part, and the friction part are integrally formed, wherein a gap prevents molten metal from overflowing between the wall part and the coupling part, interface is formed on the periphery of the coupling part, an overflow is provided outside the wall part opposite the gap; a first injection process of injecting a first material to form the friction part; and a second injection process of injecting a second material to form the coupling part, a mold for producing the brake disc, and the brake disc.

Abstract: A turbocharger housing has a valve device. The valve device is formed with at least one first duct section and a second duct section. The two duct sections are arranged with their longitudinal axes parallel to one another and they are formed without any undercuts.

Abstract: The present disclosure is directed to a refractory metal core for use in forming varying thickness microcircuits in turbine engine components, a process for forming the refractory metal core, and a process for forming the turbine engine components. The refractory metal core is used in the casting of a turbine engine component. The core is formed by a sheet of refractory metal material having a curved trailing edge portion integrally formed with a leading edge portion.

Abstract: A method for casting a thrower for a railcar coupler includes creating a mold box that is vertically parted in halves, each half defining a side of a thrower cavity and that includes at least a portion of a sprue at a location above the thrower cavity, the thrower cavity also being oriented vertically; pouring molten metal into the mold box through the sprue and into the thrower cavity while the mold is oriented vertically; and shaking out the mold box to release the thrower after the thrower has cooled. Creating the mold box may be executed through a cold shell process. The halves of the mold box may include reflective images of the sides of two thrower cavities and an ingate connected between the sprue and one of the two thrower cavities.

Abstract: A barrel spring (10) for a mechanism driven by a mainspring, in particular for a timepiece, includes a unitary ribbon of metallic glass. The object is to integrate at least one additional function to the spring function, implemented by a functional portion integrated in the spring.

Abstract: Provided are methods of replacing drilling holes in castings by pre-tensioning sand cores. These methods are used in long cylindrical shaped sand cores in cold core box processes. The urethane sand core is placed in compression to increase the core strength during handling, placing inside of the mold. The pre-tensioned urethane sand core is set in a casting mold so as to form a cavity in the casting mold. The molten metal is poured to form the cavity inside of the casting. The pre-tensioned urethane sand core maintains its initial shape during casting.

Abstract: A design for a casing of a large turbine is described with the casing including at least a front section, a middle section and an end section designed such that changes to the mold of the casing required to provide for a change in rotational speed to adapt the turbine to a different power grid frequency are limited to the mold for the middle section of the casing.

Abstract: An example method of manufacturing an airfoil includes providing a ceramic core corresponding to an interior cooling channel. A refractory metal core is provided that corresponds to a cooling passage. The cores are arranged in a mold. An airfoil structure is cast about the cores to provide a turbine engine airfoil. The turbine engine airfoil includes a wall providing the interior cooling channel and an exterior airfoil surface. The cooling passage is provided in the wall and fluidly connects the interior cooling channel to the exterior airfoil surface. The cooling passage includes multiple inlets and multiple outlets respectively adjoining the interior cooling channel and the exterior airfoil surface. At least one of a first inlet and outlet has a different structural flow characteristic than at least one of a second inlet and outlet.

Abstract: A method for manufacturing particles includes depositing on a substrate a layer of a first sacrificial material; depositing on the layer of the first sacrificial material a layer of a second sacrificial material that is different from the first sacrificial material; forming cavities in the layer of the second sacrificial material, the forming including pressing a structured mold against the layer of second sacrificial material; depositing a material for manufacturing the particles, the material covering the layer of the second material and at least partially filling the cavities; selectively removing the second sacrificial material from the first sacrificial material so as to obtain the particles formed by the material and arranged on the layer of the first sacrificial material; and eliminating the first sacrificial material to release the particles.

Abstract: A wind turbine component having a lightweight structure is provided and includes a metallic matrix defining a cavity, metallic foam enclosed within the cavity and a solidification metallurgical bond formed at an entire interface between the metallic matrix and the metallic foam.

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

Abstract: A composite ballistic armor or other composite component may be formed by encapsulating one or more ceramic elements in a casting shell and introducing molten base metal into the casting shell, such that the molten base metal encapsulates the one or more ceramic elements to form the composite component. Prior to the pouring process, the ceramic elements are pre-heated to, or near, the melting point temperature or pouring temperature of the encapsulating metal. Additionally, the cooling rate following the metal pour may be less than a predetermined rate for a predetermined period of time. The encapsulating metal may comprise, for example, a steel alloy, such as 4140 or 8630 AISI, a stainless steel alloy, or FeMnAl.

Abstract: One embodiment of the present invention is a unique method for forming a cast porous article. Other embodiments include apparatuses, systems, devices, hardware, methods, and combinations for forming cast porous articles. Further embodiments, forms, features, aspects, benefits, and advantages of the present application shall become apparent from the description and figures provided herewith.

Abstract: This invention provides a mold for injection molding and a method of manufacturing thereof. The method of manufacturing a mold for injection molding includes the following steps. At least one temperature control element is provided. The temperature control element is covered with a first material. The first material is mechanically processed to form a mold body with a cavity. The mold for injection molding includes a mold body, a temperature control element, and a heat insulating layer.

Abstract: A method of manufacturing a side frame mold for casting a side frame of a railway car truck includes forming a drag and a cope portion of a mold from a casting material to define an exterior surface of a drag portion and cope portion, respectively, of the side frame. The mold includes a portion for casting the pedestal jaw of the side frame. The drag and the cope portions are then cured.

Abstract: A method of casting a core includes the steps of preparing a first half of a corebox, preparing a second half of a corebox such that the parting line of a core formed from the first and second coreboxes runs along the vertical axis of the core.

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 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 method for manufacturing cores utilized in conjunction with a mold for casting a side frame of a railway car truck includes forming separate drag and cope portions of at least one pedestal core. The drag and cope portions of the pedestal core define an interior region of a pedestal of the side frame. The drag and cope portions are attached form a pedestal core for insertion into a mold.

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, then forming at least one core insert in-situ adjacent and fused to the at least one preformed core insert by introducing fluid fugitive pattern material into a composite core insert mold whereby the fugitive core inserts are integrally connected as a single composite core insert that includes features to form internal passage surfaces in the core when the composite core insert is removed. The composite core insert is placed in a core molding die cavity, and a fluid ceramic material is introduced into the die cavity to form the ceramic core body incorporating the fugitive composite core insert therein.

Abstract: An evaporative pattern casting process includes forming a mold by burying a pattern made of resin foam in casting sand, pouring molten metal into the mold, and evaporating the pattern with the molten metal and thereby casting a product. In the evaporative pattern casting process, casting time during founding is set according to a modulus (pattern volume÷pattern surface area) of the pattern. Accordingly, the casting time in the evaporative pattern casting process is accurately set with high precision.

Abstract: A mould for casting metal which allows solid impurities to be removed from the molten metal. The mould (50) has a cavity therein, said cavity having a casting portion and contiguous therewith a running system upstream of the casting portion, said running system comprising an upstream inlet portion (58), a downstream outlet portion (60) and a swirl chamber (54) disposed between the inlet and outlet portions (58, 60), wherein a filter (62) is provided at an interface between the swirl chamber (54) and the outlet portion (60). The application also relates to a method for preparing the mould, a pattern for preparing the mould, a housing for use in the mould and a method for casting employing the mould.

Abstract: An injection method for hollow products, a fusible core and the method for making the fusible core comprises putting a fusible Sn—Bi alloy core into a mold core, then both the product and the fusible core are taken out from the die. The fusible core is turned from solid to liquid state and is apart from the product. The inner wall of the core can be made using this method, and the plastic product can be with more shape in one-step molding to replace the metal in many fields. Complex core-pulling mechanism is not needed, thus the core structure is simplified, and the shape of die can be simplified. The fusible core is not needed to be maintenance for it will not be worn, because after each injection, the fusible core is recycled to make a new fusible core.

Abstract: A turbine bucket for use with a turbine engine. The turbine bucket includes a dovetail that is coupled to a rotor assembly that is positioned within a turbine casing. A platform extends from the dovetail. An airfoil extends from the platform. The airfoil includes a root end and a tip end. The tip end extends outwardly from the root end towards the turbine casing. A tip shroud extends from the tip end. The tip shroud includes a shroud plate. A first shroud rail extending a first radial distance from the shroud plate towards the turbine casing. A second shroud rail extends a second radial distance from the shroud plate towards the turbine casing that is different than the first radial distance.

Abstract: A method of creating an article from investment casting includes forming a ceramic seed well, heating the ceramic seed well to form a hardened ceramic seed well, attaching a meltable pattern to the hardened ceramic seed well, coating the hardened ceramic seed well and the meltable pattern with hardenable ceramic material, heating the hardenable ceramic material to melt the meltable pattern, removing the meltable pattern from the hardenable ceramic material, firing the hardenable ceramic material to form a ceramic mold having a cavity, placing a seed within the hardened ceramic seed well, and pouring molten metal into the hardened ceramic seed well and the cavity. The cavity of the ceramic mold is in communication with the hardened ceramic seed well.

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: An impeller (2) for a pump is designed as a casting and includes at least one blade (4). The impeller (2), when casting, is molded by way of at least two core parts (14, 16). Partition lines (26, 28) between the at least two core parts (14, 16) are distanced to an end-edge (10) of the at least one blade. The end-edge is at a front in a flow direction (S).

Abstract: A mold including a product cavity that is to be filled with a molten metal to mold a product; a supply cavity that connects to one side of the product cavity to supply the product cavity with the molten metal that is poured from a casting port; and a cooling cavity that connects to the other side of the product cavity and in which the molten metal filling the cooling cavity is cooled before the molten metal filling the product cavity and the supply cavity is cooled. A modulus M (=V/S) as a ratio of a volume V to a cooling surface area S in each of the cavities has a relation of Ms>Mp>Mc, where Mp is a modulus of the product cavity, Ms is a modulus of the supply cavity, and Mc is a modulus of the cooling cavity.

Abstract: A mold boring apparatus including a mold boring tool having a flow passage formed inside of the mold boring tool which allows a fluid to flow therethrough, having slits and protruding portions formed on an outer peripheral portion of an outer body of a tool blade member of the mold boring tool in a circumferential direction thereof extending from a leading end to a base end of the tool blade member, and blades that are inclined inward and are formed at leading ends of the protruding portions formed between the adjacent slits.

Abstract: Solder mold plates and methods of manufacturing the solder mold plates are provided herein. The solder mold plates are used in controlled collapse chip connection processes. The solder mold plate includes a plurality of cavities. At least one cavity of the plurality of cavities has a different volume than another of the cavities in a particular chip set site. The method of manufacturing the solder mold plate includes determining susceptible white bump locations on a chip set. The method further includes forming lower volume cavities on the solder mold plate which coincide with the susceptible white bump locations, and forming higher volume cavities on the solder mold plate which coincide with less susceptible white bump locations.

Abstract: Nanostructured assemblies are manufactured by condensing an evaporated wetting agent onto a nanostructure array formed from a plurality of generally aligned carbon nanotubes or other nanostructures. The condensed wetting agent draws the individual nanostructures together to form various geometries of nanostructured assemblies based on various parameters including process variables and the starting shape and dimensional features of the nanostructure array. Various simple and complex geometries can be achieved in this manner, including geometries that are curved, bent, or twisted. Adjacent nanostructure arrays of the same or different starting geometries can be shaped into compound or interrelating structures. Additional process steps such as plasma etching, coating and others can be used to control the shaping and structural attributes of the nanostructured assemblies. A method of making a molded replica of a shaped nanostructure array is also disclosed.

Abstract: Described are methods for making microstructured flexible molds, for example useful for making microstructured metal objects in a casting process. Also described are casting methods for making microstructured epoxy objects. In some embodiments, the microstructured metal and epoxy objects are useful for embossing polymer sheets to form microstructured polymer sheets.

Abstract: The invention relates to a process for producing a twist-beam axle, which respectively has a light metal longitudinal link and an iron metal transverse arm. The invention proposes a process comprising at least the following steps: a casting mold is produced for the respective longitudinal link, an appropriate end of the transverse arm is inserted into a corresponding recess in the casting mold, only then is liquid light metal poured into the casting mold for the longitudinal link, the light metal melt introduced into the casing mold is allowed to cool, the cooled light metal joined to the end of the transverse arm is removed from the casting mold.