Abstract: A method of manufacturing a valve body having one or more corrosion-resistant internal surfaces. The method involves performing a casting process, which includes pouring a first material into a mold box, to produce a valve body casting made of the first material. During the casting process, a layer of a second material is formed on one or more internal surfaces of the valve body casting, the second material having a higher corrosion resistance than the first material, by: (1) applying, with an additive manufacturing technique, the second material to one or more external surfaces of a core, and (2) inserting the core into the mold box. A portion of the first material binds to the second material on the one or more external surfaces of the core while the first material is poured into the mold box.

Abstract: A method of manufacturing a replacement body for a component is provided. The method includes the steps of: a) additively manufacturing a crucible for casting of the replacement body; b) solidifying a metal material within the crucible to form a directionally solidified microstructure within the replacement body; and c) removing the crucible to reveal the directionally solidified replacement body.

Abstract: A method of manufacturing a component includes additively manufacturing a crucible; directionally solidifying a metal material within the crucible; and removing the crucible to reveal the component. A component for a gas turbine engine includes a directionally solidified metal material component, the directionally solidified metal material component having been additively manufactured of a metal material concurrently with a core, the metal material having been remelted and directionally solidified.

Abstract: A method of working an additively manufactured part includes applying a layer of wax to a part manufactured with an additive manufacturing process. Then a mold is formed over the layer of wax on the part. The wax is then removed from between the mold and the part. The part is then melted in the mold, and then the part is re-solidified in the mold. Finally, the mold is removed.

Abstract: A furnishing element with a conditioning function, which includes a base structure having a determinate aesthetic and/or functional conformation for furnishing, and one or more conditioning components, able to carry out a heat exchange with the environment to determine the conditioning thereof. The base structure defines at least a radiant surface and is made by lost mold casting. The mold or core used for casting is destroyed at the end of casting. The conditioning components are constrained to the base structure and are suitably shaped to be disposed in proximity to the radiant surface, so that the radiant surface determines a desired radiation, able to condition a room and/or one or more users.

Abstract: A bi-cast turbine rotor disk and method of forming the same are provided. The disk includes a ring and a blade. The ring comprises a superalloy that includes a plurality of elements, and the blade extends from the ring. The blade comprises a non-metallic ceramic matrix composite, and at least one element from the superalloy of the ring is diffused into the non-metallic ceramic matrix composite of the blade.

Abstract: A vulcanizing mold manufacturing method, and a tire vulcanizing mold are disclosed. Tubular bodies each formed by oppositely arranging the inner peripheral surfaces of both end portions of a plate-shaped body are each arranged so that the gap between both opposite end portions thereof is narrowed and that the tips of both end portions come in contact with the surface of the plaster mold, by inserting and fitting both opposite end portions into a fitting portion of a plate-shaped metal fitting protruding from the surface of the plaster mold. Molten metal is poured over the surface of the plaster mold to embed the tubular body in a mold while exposing the tips of both opposite end portions at the tire molding surface of the mold. The metal fitting is removed from the mold, so that a mold having a small gap between both opposite end portions is manufactured.

Abstract: A tire vulcanization mold manufacturing method can manufacture a tire vulcanization mold having an exhaust mechanism capable of ensuring sufficient exhaust with fewer processing steps. When a mold having a surface of a gypsum mold transferred to the mold is to be manufactured by pouring molten metal onto the surface of the gypsum mold and solidifying the molten metal, a tubular body having a slit allowing hollow inside to communicate with the outside is disposed in such a way that the slit is brought into contact with the surface of the gypsum mold. Thereafter, the molten metal is poured onto the surface of the gypsum mold in such a way that the tubular body is buried in the mold while the slit is exposed on a tire molding surface of the mold.

Abstract: A brazing system for brazing component members of a workpiece has a brazing chamber an inside of which is made a heating space of a volume corresponding to the workpiece, a radiant heating means provided with a plurality of heating sources which are positioned so as to correspond to a plurality of regions into which two facing surfaces of the workpiece are respectively divided, a convection heating means for circulating a heated inert gas to the heating space so as to heat the workpiece, and a control means for controlling the operation of the heating sources and the circulation of the inert gas. Each heating source is independently controlled by the control means, and the convection heating means circulates the inert gas so as to reduce a temperature difference of the workpiece caused by the heating sources.

Abstract: A down hole tool casting assembly, a gauge ring, and a method for preparing the gauge ring for use within the assembly. The gauge ring includes a bit diameter mold and one or more junk slot displacements extending inwardly from the interior surface of the bit diameter mold. The junk slot displacement includes a first end, a second end, and a junk slot displacement face extending from the first end to the second end. At least one groove is formed within the interior surface of the gauge ring, which alleviates stresses formed within the casting during the casting process. According to some embodiments, at least one groove is formed within the junk slot displacement face. According to some embodiments, at least one groove is formed within the interior surface of the bit diameter mold. Optionally, a pressure absorbing material is inserted into one or more grooves.

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

Abstract: The invention relates to a structure for producing castings, which comprises an organic fiber, carbon fiber, inorganic particles, and at least one kind of thermosetting resin selected from the group consisting of phenol resin, epoxy resin and furan resin.

Abstract: Alloy products are produced with a waxless casting process. A model of a ceramic casting vessel (34) defining a desired product shape is digitally divided into sections (10, 40, 42). Each section is translated into a soft alloy mater tool (14) including precision inserts (20) where needed for fine detail. A flexible mold (24) is cast from each master tool, and a section of the ceramic casting vessel is cast from the respective flexible mold. The vessel sections are assembled by aligning cooperating precision features (58, 60) cast directly into each section and the alloy part is cast therein. No wax or wax pattern tooling is needed to produce the cast alloy product. Engineered surface features (54) may be included on both the interior and exterior surfaces of the shell sections.

Abstract: A mold usable to form a drill bit body and a method for forming such a mold are disclosed. A shell is provided, the shell having a cavity. Fusible material, such as foundry sand, is provided into the cavity, then fused to form a solid insert within the shell. The solid insert is then modified, such as by machining, to form a mold having features usable to form a drill bit body having desired characteristics. Materials for forming the drill bit body can then be provided into the mold, for heating and cooling. Then, the drill bit body and mold can be removed from the shell. The shell is thereby reusable, while the mold, being formed from inexpensive fusible materials, can be removed or destroyed, if necessary, to free the drill bit body.

Abstract: A brake caliper for a disk brake system of a motor vehicle, has a caliper body which is cast from a light metal alloy or from light metal, with a skeleton structure arranged inside the caliper body. The material of the skeleton structure has a higher modulus of elasticity than the material of the caliper body. The skeleton structure is cast into the caliper body so that the caliper body encases the skeleton structure.

Abstract: A turbine blade or turbine vane includes a metallic nonfoam region, and a ceramic foam region joined to the metallic region. The ceramic foam region is an open-cell solid ceramic foam made of ceramic cell walls having an intracellular volume therebetween. The ceramic is preferably alumina. The intracellular volume may be empty porosity, or an intracellular metal such as an intracellular nickel-base superalloy.

Abstract: An engine block mold package includes a barrel crankcase core having a plurality of barrels on each of which a respective cylinder bore liner is disposed. Each cylinder bore liner includes an inside diameter that is tapered along at least a portion of its length to match a draft angle present on the barrels to permit removal of the barrel crankcase core from a core box in which it is formed.

Abstract: An engine block mold package is assembled from resin-bonded sand cores in a manner that reduces contamination of the engine block cast in the mold package by loose sand abraded off the cores during assembly. An assembly of multiple cores (core package) of the engine block mold package is formed apart from a base core. The core package is cleaned to remove loose sand therefrom. The cleaned core package then is positioned on the base core followed by assembly of a cover core to complete the engine block mold package for casting of an engine block therein.

Abstract: In assembly of engine block mold package, a water jacket slab core is assembled on a barrel crankcase core having a plurality of barrels on which cylinder bore liners are positioned. Some of the barrels include a core print on a distal end thereof. The water jacket slab core includes a plurality of core prints each in mating relation with a respective barrel core print and a plurality of bore liner positioning surfaces that each engage a respective distal end of a respective cylinder bore liner when the water jacket slab core is assembled on the barrels.

Abstract: An engine block mold package is assembled from resin-bonded sand cores in a manner that reduces parting lines on the exterior surfaces of the mold package. An assembly of multiple cores (core package) is formed and includes multiple inter-core parting lines extending in different directions on exterior surfaces of the core assembly. The core package is disposed between a base core and a cover core configured to enclose the core package and form a single continuous exterior parting line about the assembled mold package.

Abstract: A tool (40) has a ledge portion (46) and a cutting blade portion (50) for cutting a groove (24, 26, 28) in a wax model (32) for an article of jewelry. The groove is formed after the wax model is formed by mechanical removal of the wax, preferably by cutting with tool (40). The wax model and gems are then placed in an investment mold where the lost wax technique is used to form an article of jewelry with the gems set therein.

Abstract: A device for manufacturing an engine block has a casting mold with mold parts and cylinder liners. The mold parts have a seat with seat surfaces for each cylinder liner, and the opposed ends of the cylinder liner are seated in the seat surfaces. The cylinder liners become connected to the material cast in the casting mold and are removed together with the cast material from the mold parts after casting. The seat surfaces are conical and inclined at an incline angle relative to the cross-sectional plane of the cylinder liner seated in the seat such that the opposed ends of the cylinder liner remain seated at the seat surfaces upon heat expansion of the cylinder liner during preparation of the casting mold for casting and during casting.

Abstract: A device for making a mold for molding at least a portion of a tread of a re using a countermold and a pourable, solidifiable material. Molding elements are transferred from the countermold and imbedded in the tire tread mold in protruding fashion by placing each molding element in a housing of the countermold before the actual molding of the tire tread mold and in such a manner as to permit easy transfer from the countermold to the tire tread mold.

Abstract: A method of manufacturing gem decorated articles, typically jewelry, includes the steps of: using a first mold which has a mold cavity with one or more gem portions for receiving one or more gems and duplicates a model of the article; positioning one or more gems in the mold gem portion(s) of the mold; forming a temporary bond between the gem(s) and the mold gem portion(s) of the mold to maintain the gem(s) in place in the mold gem portion(s) during formation of a wax model including the gem(s); introducing a molten, hardenable wax material into the mold; cooling the wax material to form a wax model reproduction of the article with the gem(s) set therein; ending the temporary bond between the gem(s) and the mold gem portion(s) of the mold; removing the wax model with the set gem(s) from the mold; applying an investment material about the wax model with the set gem(s) and hardening the investment material to form a second mold; removing the wax material from the second mold; introducing a molten metal into the

Abstract: A plurality of inter-connected cores includes barrel cores (18). Bore liners (10) surround the barrel cores (18) and are fixed in relation thereto. A cylinder block mold core package (22) is assembled from the cores (14, 24, 26, 28). The liners (10) are heated while they are within the cylinder block mold core package (22) by induction heating. To prevent migration, a mechanical interlock is provided between each liner (10) and its associated barrel core (18).

Abstract: A core material for making cores to be used in molds for the casting of metals and comprising a mixture of hollow ceramic particles uniformly distributed throughout a resin binder of organic material. The hollow ceramic particles are individually in intimate surface contact with adjacent individual hollow ceramic particles throughout the core materials to allow the heat of the casting to be conducted efficiently through the core material. The amount of resin binder being maintained at a minimum to reduce the amount of gas generated by the resin binder as it is exposed to the heat of the metal being cast. The hollow ceramic particles comprising about 99.0 to about 96.5% by weight of the core material and the resin binder comprising about 1.0 to 3.5% by weight, respectively, of the core material prior to the core material being cured, and the hollow ceramic particles preferably ranging in diameter from about 200 microns to about 450 microns, with a preferred mean diameter of about 325 microns.

Abstract: A rigid bar (or segment) on which stones will be at least partially supported is positioned in a rubber mold for creating a wax pattern of the jewelry, injecting wax to form a wax model of the jewelry including the metal bar to fit into an incision in the stones. The model with the metal bar forms the invisible pre-set stone mount. Stones are then placed into set position in the wax pattern on opposite sides of the metal bar. Once the setting is complete, the jewelry is created using known "lost-wax" method of manufacturing jewelry.

Abstract: At least one preliminary pattern body, which is then used as part of a pattern or the pattern itself, is produced with fibers and a pattern material. A ceramic mold is formed around the pattern with a portion of the fibers having ends embedded into the mold. The pattern material is removed and finally, metal in liquid, liquid-solid or powdery form is introduced into the mold, wherein the metal is at least partially liquefied in the mold when it is introduced in powdery form. This process allows investment castings having an increased resistance to be produced with relatively simple casting equipment.

Abstract: The golf club head comprises a head body which defines the front striking face of the club head. Disposed within the head body is a ceramic insert which defines the rear face of the club head. The head body is cast about the insert in a manner wherein the insert is partially encapsulated by the head body and rigidly captured therewithin.

Abstract: A decomposable casting core (56a, 56b) is formed in-situ with a sleeve-like liner member (64) and the assembly mounted within the mold cavity (24) of a cylinder block casting mold (22) for lining piston cylinder chambers (62a, 62b) of a cylinder block (26) cast within the mold (22). The liner member (64) is formed with an inner annular recess (80) which receives a corresponding annular projection (76) of the core (56a, 56b) for preventing the liner (64) from sliding axially on the core (56a, 56b) during casting.

Abstract: A method of manufacture of a net form product, including directing a stream of liquid from a nozzle onto a collector of the shape of the desired product, applying an amplitude and time dependent modulated disturbance to the stream to produce a droplet stream, and with the nozzle and collector in a chamber, controlling the chamber environment. An apparatus for manufacturing a net form product having a source of molten material under pressure, a support for positioning a product collector in a chamber with the collector defining a desired product, a droplet stream generator positioned within the chamber and including a nozzle, a conduit for conducting molten material from the material source to the generator nozzle, a mechanism, typically a modulator, for amplitude and time dependent modulation disturbance of the droplet stream, and a drive mechanism for relative movement of the nozzle and support.

Abstract: A method of manufacture of a net form product, including directing a stream of liquid from a nozzle onto a collector of the shape of the desired product, applying a disturbance to the stream, preferably an amplitude modulated disturbance, to produce a droplet stream, and with the nozzle and collector in a chamber, controlling the chamber environment. An apparatus for manufacturing a net form product having a source of molten material under pressure, a support for positioning a product collector in a chamber with the collector defining a desired product, a droplet stream generator positioned within the chamber and including a nozzle, a conduit for conducting molten material from the material source to the generator nozzle, a mechanism, typically a modulator, for disturbing the droplet stream, and a drive mechanism for relative movement of the nozzle and support.

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

Abstract: An aluminum metal matrix composite comprises an aluminum metal matrix embedding a second filler, such as a ceramic second filler, and is formed by contacting, for example, a molten aluminum metal with a permeable mass of second filler within a ceramic impervious mold formed by growing a polycrystalline oxidation reaction product into a first filler. By hermetically sealing the second filler within the mold with a body of molten aluminum metal, the latter spontaneously infiltrates the mass of second filler at moderate temperatures, e.g. about 900.degree. C., without need of any other infiltration expedients. The molten mass containing the infiltrated ceramic filler is solidified to provide the metal matrix composite which may be recovered from the mold.

Abstract: This invention relates to a production method of a mold for continuous casting comprising the steps of: providing a cooled water path in the mold water cooling mechanism; filling the cooled water path with a wax; making the wax surface uniform; providing a copper or copper alloy stratum on the wax surface by electrolytic plating; removing wax from the cooled water path and uniting the mold water cooling mechanism with the mold as one; and comprising the additional step of providing a copper or nickel plating on the surface on which is provided the cooled water path in the mold water cooling mechanism before depositing wax in the path.

Abstract: An aluminum metal matrix composite comprises an aluminum metal matrix embedding a second filter, such as a ceramic second filler, and is formed by contacting, for example, a molten aluminum metal with a permeable mass of second filler within a ceramic impervious mold formed by growing a polycrystalline oxidation reaction product into a first filler. By hermetically sealing the second filler within the mold with a body of molten aluminum metal, the latter spontaneously infiltrates the mass of second filler at moderate temperatures, e.g. about 900.degree. C., without need of any other infiltration expedients. The molten mass containing the infiltrated ceramic filler is solidified to provide the metal matrix composite which may be recovered from the mold.

Abstract: A cast-in member and a heating member are set in a mold with the cast-in member being in the vicinity of the heating member. Molten metal is poured through an ignition runner into contact with the heating member to ignite the latter and produce heat. The cast-in member is heated with the heat from the heating member. Thereafter, molten metal is poured through a runner into a cavity in the mold to cast the metal around the cast-in member.

Abstract: A method for selectively coating inexpensive accessories with expensive multi-metals sequentially by utilizing an apparatus of a cylinder member, standing member, wax rod, and glass housing for producing fine products which are coated with colorful expensive multi-metals.

Abstract: A core assembly is formed by molding a destructible plastic form around at least one insert and optionally around a non-destructible core. The core assembly can be used, for example, for casting engine cylinder heads having valve seat inserts integral therewith. The plastic form retains and supports the inserts until the precise time the plastic is replaced by the molten metal.

Abstract: A process of forming a high alloy layer on a surface of an aluminum alloy casting. The process comprises steps of providing a mixture of fine powders having an average powder size finer than 10 microns, preferably finer than 1.0 micron, of an alloying metal or an alloying alloy and an acrylic binder, shaping the mixture into a sheet, heat treating the sheet at 150.degree. to 380.degree. C. for more than 5 minutes, placing the heat treated sheet on a surface of a casting mould or a chilling block, and casting molten aluminum alloy.

Abstract: A hollow metallic envelope 10 of a finned cast recuperator tube is cast with preformed interior fins 12 and exterior fins 16 integral therewith. A sand core 30 is formed about the preformed interior fins 12 with portions of the fins 12 protruding outwardly from the sand core, and a sand mold 40 is formed to a cavity for receiving the sand core 30 with the preformed exterior fins 16 embedded in the sand mold with portions of the fins 16 protruding therefrom into the cavity. The sand core 30 is placed into the sand mold 40 in spaced relationship therewith so as to provide a clearance space 50 between the sand core 30 and sand mold 40 into which the portions of the interior fins 12 and exterior fins 16 extend. Molten metal is poured into the space 50 which upon cooling solidifies to form the envelope 10 with the interior fins 12 and exterior fins 16 fused integrally therewith.

Abstract: A method of forming a socket with a cast-in spherical ball having a central opening formed therethrough. The method includes preparation of a core assembly to incorporate the ball such that a portion of the circumference of the ball surface defines a portion of the casting cavity forming a race surface for the ball.

Abstract: Articles of jewelry with gems set in precious metal are cast by a modified lost wax method whereby each gem is retained in position in the investment mold after removal of the wax enabling the setting of the gem to be simultaneous with the casting of the precious metal. The wax model of the article of jewelry is molded with undercut grooves in the sidewall of the gem seat located to engage portions of the girdle of the gem for retention thereof in set position in the finished article. The wax for the model is formulated to provide resiliency to permit the gem to be snapped into position in the wax model prior to embedding the model with the gem set therein in investment material in the conventional flask. Curing time is reduced to approximately one half the conventional fourteen hours by precise control of predetermined time and temperature which also prevents marring of the gems during the curing of the investment and the casting of the precious metal.

Abstract: A finished ceramic airfoil is provided having within it a lining of thermal insulation and a fusible core having the desired contour of the metal core of the turbine blade. A casting mold is provided around the airfoil. The fusible core is melted and removed, leaving a cavity in the airfoil surrounded by the insulation lining. The cavity is filled with molten metal which is allowed to solidify to form the metal core of the turbine blade.

Abstract: The invention relates to fixing a metal strength member on a non-metal part. A heat-resistant fibre glass layer is inserted between the strength member and the non-metal part, the layer extending throughout at least the zone of the non-metal part which corresponds to the point where the molten metal which forms the strength member is injected and being coated with a non-adhering inert inorganic substance so that the layer is thus compressed between the non-metal and the metal part when the metal part is applied against the non-metal part. Application in particular to manufacturing tempered glass electric insulators with moulded aluminium caps.

Abstract: A method of producing a heat exchanger in which a fin block of porous metal and fin plates connected to the fin block are unitarily secured to a serpentine heat-transmitting pipe. A plurality of fin molds produced with the use of plastic patterns formed therein with continuous, three-dimensional cavities are assembled with the heat-transmitting pipe shaped beforehand into a serpentine form in such a manner that the fin molds enclose the heat-transmitting pipe with suitable spacing intervals defined between the fin molds themselves and between the fin molds and the heat-transmitting pipe. Molten metal of high thermal conductivity is cast into continuous cavities in the fin molds and into the spacing intervals, and the material of the fin molds is removed after the molten metal has solidified.

Abstract: A core unit for use in casting a cylinder block of an internal combustion engine which core unit comprises a preformed cylinder liner which includes a cylindrical sidewall defining an interior bore and having a port in the sidewall. A first core unit is formed of a reducible material molded upon the preformed liner, which first core unit includes a first main core portion which partially occupies the bore and a port core portion which extends through the port. A second core unit is formed of the reducible material separately from the first core unit and is assembled upon the cylinder liner, which second core units includes a second main core portion in the bore and in mating alignment with the first main core portion, thereby forming a composite core assemblage. The composite core assemblage is placed into a cylinder block mold, and molten metal is caused to enter the cylinder block mold, thereby forming a cylinder block surrounding the composite core assemblage.

Abstract: A composite article and method of forming the same wherein an inner casting is separated from an outer casting by an insulative portion defining the pattern for the outer surface of the inner casting and the pattern for the inner surface of the outer casting. The insulative portion is captured between the castings to define a thermal barrier therebetween. The castings are formed by gasifying an expendable gasifiable pattern corresponding to the inner and outer castings, respectively. The patterns are assembled with the insulative portion of the article disposed therebetween and a mold is formed about the assembled patterns and insulative portion. Upon pouring of molten casting metal into the mold, the expendable patterns are gasified into the mold, permitting the inner and outer portions of the article to be cast about the insulative portion to form the desired final composite article.

Abstract: A method and apparatus for insulating the exhaust passage of an internal combustion engine is disclosed. A three-zone liner assembly is provided with an outer zone comprised of a room temperature vulcanizing silicone sleeve, an inner zone comprised of a stamped and seam welded high strength Al-Cr-steel alloy, and an intermediate zone consisting of a ceramic wool mat. The liner assembly is supported or enclosed within a mild carbon sheet metal sleeve which in turn may be bonded to the engine passage wall by use of a room-temperature-vulcanized silicone if of the insert type, or by fusion bonding during casting if of the cast-in-place type.

Abstract: A rigid bar (or segment) on which stones will be at least partially supported is positioned in a rubber mold for creating a wax pattern of the jewelry, injecting wax to form a wax model of the jewelry including the metal bar to fit into an incision in the stones. The model with the metal bar forms the invisible pre-set stone mount. Stones are then placed into set position in the wax pattern on opposite sides of the metal bar. Once the setting is complete, the jewelry is created using known “lost-wax” method of manufacturing jewelry.