Способ изготовления моделей из пенополистирола для получения композиционных отливок методом литья по газифицируемым моделям

Изобретение относится к литейному производству. Способ изготовления моделей из пенополистирола включает установку в пресс-форму по меньшей мере одного элемента, улучшающего механические свойства отливки и фиксируемого в модели, засыпку гранул пенополистирола и вспенивание гранул в пресс-форме. Пресс-форму заполняют послойно предварительно вспененными гранулами пенополистирола, а сверху каждого слоя устанавливают по меньшей мере один фиксируемый элемент, улучшающий механические свойства отливки. На поверхность по меньшей мере одного фиксируемого элемента, улучшающего механические свойства отливки предварительно наносят легирующие элементы или соединения. Обеспечивается фиксация элемента, улучшающего механические свойства отливки в требуемых участках модели, в зависимости от требований, предъявляемых к отливкам. 2 н. и 7 з.п. ф-лы, 5 пр.

КОМПОЗИЦИЯ ДЛЯ ИЗГОТОВЛЕНИЯ ВЫПЛАВЛЯЕМЫХ МОДЕЛЕЙ

Изобретение относится к литейному производству и может быть использовано для литья лопаток и других деталей ГТД сложной конфигурации. Композиция для изготовления выплавляемых моделей содержит, мас.%: твердый углеводород, и/или воск - 0,1-80, и/или полимер с температурой плавления до 300°C - 0,05-30, углеводородную смолу - до 80, фталевые кислоты - до 70, краситель - до 1,5 и полистирол или бисфенол - до 70. Обеспечивается повышение прочности, твердости, трещиностойкости и теплоустойчивости, снижение зольности, улучшение качества поверхности моделей и контроль выявляемости дефектов на изделии. 3 з.п. ф-лы, 2 табл.

ЛИТЕЙНАЯ ФОРМА ДЛЯ МОНОКРИСТАЛЛИЧЕСКОГО ЛИТЬЯ

Изобретение относится к области монокристаллического литья, в частности к литейной форме для монокристаллического литья, а также к ее изготовлению и способу вакуумного литья металлического материала с использованием упомянутой литейной формы. Литейная форма содержит литейную полость, содержащую первый объем и второй объем, расположенный на первом объеме в соединении с ним и имеющий по меньшей мере один горизонтальный выступ относительно первого объема, и зерновой канал с нижним концом, соединенным с первым объемом, и с верхним концом, расположенным рядом с указанным горизонтальным выступом второго объема, при этом она включает в себя разделительный элемент, расположенный между указанным вторым объемом литейной полости и верхним концом зернового канала так, чтобы разделять их. Изобретение позволяет создать литейную форму для отливки деталей с большим горизонтальным боковым выступом, соответствующим полке лопатки турбомашины. 3 н. и 6 з.п. ф-лы, 5 ил.

УСОВЕРШЕНСТВОВАННЫЙ СПОСОБ ИЗГОТОВЛЕНИЯ ПО ВЫПЛАВЛЯЕМОЙ ВОСКОВОЙ МОДЕЛИ КОЛЬЦЕВОГО ЛОПАТОЧНОГО УЗЛА ТУРБОМАШИНЫ, МЕТАЛЛИЧЕСКАЯ ФОРМА И ВОСКОВАЯ МОДЕЛЬ ДЛЯ РЕАЛИЗАЦИИ ТАКОГО СПОСОБА

Изобретение относится к литейному производству. Восковая модель (50) кольцевого лопаточного узла статора турбомашины содержит радиально внутренний (52) и радиально внешний (54) коаксиальные экраны, соединенные друг с другом лопатками (56), из которых по меньшей мере одна лопатка (58) имеет внутреннюю полость. Для получения восковой модели в металлической форме размещают стержень (40) для образования оттиска полости лопатки (18), который выполнен из металла, впрыскивают воск в форму и извлекают восковую модель, содержащую стержень (40), из формы. Стержень располагают в форме так, что его радиально внутренний конец размещается на участке (58) формы, образующем лопатку с полостью, на расстоянии от радиально внутреннего конца (52) данного участка формы. Снижается брак по восковым моделям вследствие устранения деформации стержня при инжекции воска в форму. 4 н. и 3 з.п. ф-лы, 7 ил.

СПОСОБ ИЗГОТОВЛЕНИЯ ДЕТАЛИ ЛИТЬЕМ ПО ВЫПЛАВЛЯЕМЫМ ВОСКОВЫМ МОДЕЛЯМ И ПРИ УПРАВЛЯЕМОМ ОХЛАЖДЕНИИ

Изобретение относится к изготовлению литьем по выплавляемым восковым моделям деталей из никелевого сплава со столбчатой или монокристаллической структурой. Способ включает изготовление восковой модели (20) с керамическим стержнем (10), который содержит на продольном конце первую удерживающую опору (14) и на противоположном конце вторую удерживающую опору (16), и изготовление оболочковой литейной формы (30) вокруг модели. Первая опора (14) стержня размещена со стороны основания литейной формы. Стержень (10) жестко соединен с оболочковой литейной формой средством зацепления (40) между первой опорой (14) и стенкой литейной формы (30). Вторая опора (16) стержня удерживается в литейной форме средством удержания (17), скользящим по стенке литейной формы Литейную форму основанием размещают в печи, заливают расплав никелевого сплава в литейную форму и осуществляют направленное затвердевание залитого металла путем постепенного охлаждения в направлении от пода печи. Обеспечивается устранение деформации ...

РАЗЛИВОЧНЫЙ СТЕНД И СПОСОБ СБОРКИ

Изобретение относится к области литейного производства. Разливочный стенд для литья по выплавляемым моделям (1) содержит по меньшей мере один держатель (8), по меньшей мере одну модель (2) и по меньшей мере первое охватываемое и охватывающее соединение (9), связывающее указанную модель (2) с держателем (8). Первое охватываемое и охватывающее соединение (9) содержит отверстие (13), штифт (11), по меньшей мере частично введенный внутрь отверстия (13), и тонкий слой (15) плавкого материала, расположенный между наружной поверхностью (11а) штифта (11) и внутренней поверхностью (13а) отверстия (13). Обеспечивается простота сборки разливочного стенда и простота ее автоматизации. 4 н. и 10 з.п. ф-лы, 18 ил.

КОМПОНЕНТ ГАЗОВОЙ ТУРБИНЫ, ГАЗОТУРБИННЫЙ ДВИГАТЕЛЬ, СПОСОБ ИЗГОТОВЛЕНИЯ КОМПОНЕНТА ГАЗОТУРБИННОГО ДВИГАТЕЛЯ

Компонент газовой турбины, имеющий теплоизолирующую внешнюю поверхность для воздействия газообразных продуктов сгорания, содержит металлическую подложку, крепящий слой на поверхности подложки, теплозащитное покрытие, структуру выступающих элементов и структуру элементов в виде канавок. Теплозащитное покрытие включает слой внешнего теплозащитного покрытия, имеющий внутреннюю поверхность, нанесенную поверх и сцепленную с крепящим слоем, и внешнюю поверхность для воздействия газообразных продуктов сгорания. Структура в виде выступающих элементов имеет высоту выступов, составляющую от 2 до 75% совокупной общей толщины слоев теплозащитного покрытия. Структура элементов в виде канавок имеет канавки, сформированные в ранее нанесенном слое внешнего теплозащитного покрытия, по его внешней поверхности, и проникающие в этот слой. Структура выступающих элементов и структура элементов в виде канавок находятся в соответственно ограниченных, отделенных, трехмерных, независимо выровненных структурах, проходящих ...

СПОСОБ ЛИТЬЯ, В ЧАСТНОСТИ, ГОЛОВКИ БЛОКА ЦИЛИНДРОВ ДВИГАТЕЛЯ

Изобретение относится к способу литья для изготовления деталей, имеющих внутренние полости или отверстия. Указанные отверстия и/или полости создают путем установки в литейную форму одного или большего количества литейных стержней, изготовленных, например, из песка. Основной литейный стержень получают в стержневом ящике, вместе с одним или большим количеством вспомогательных литейных стержней, предназначенных для объединения с основным литейным стержнем. По крайней мере на один вспомогательный стержень в определенных зонах и шаблонной толщиной наносят покрытие из материла, разрушаемого при контакте с расплавленным металлом. В литейном стержне и в слое покрывающего материала формируют два соосных отверстия. В указанные отверстия устанавливают направляющую для клапанов впускных и выпускных каналов головки блока цилиндров. Монолитную группу стержней с покрытием устанавливают в литейную форму для заливки металла. Литейные стержни, на которые наносят покрытие, можно формировать в виде полых вставок ...

Способ сборки блока удаляемых литейных моделей

Изобретение относится к литейному производству и может быть использовано при производстве точных отливок из черных и цветных сплавов по удаляемым моделям, в том числе полученным 3D-печатью по аддитивным технологиям. Способ сборки блока удаляемых литейных моделей включает использование механического соединения «паз-шип». Глубину паза выбирают не менее чем на 25% больше длины шипа. На посадочной поверхности шипа выполняют канавки, а перед сборкой посадочную поверхность паза нагревают до температуры на 10-15°С выше уровня температуры размягчения материала литейных моделей. Может быть использовано для механического соединения «паз-шип» в виде ласточкиного хвоста. Обеспечивается повышение надежности соединения элементов блока удаляемых моделей за счет минимизации искажения геометрии модельного блока в целом и нарушения неразъемности соединения отдельных элементов блока при сборке. 1 з.п. ф-лы, 1 ил., 1 табл.

СПОСОБ ЛИТЬЯ ПОЛОЙ ДЕТАЛИ ПО ВЫПЛАВЛЯЕМОЙ МОДЕЛИ

Изобретение относится к области металлургии и может быть использовано при изготовлении содержащей полости литой детали с помощью трехмерной цифровой координатной модели литой детали с использованием керамической формы. Способ включает следующие этапы: изготовление сердечника по трехмерной модели в рамках первого метода изготовления с использованием ЧПУ; позиционирование сердечника в держателе для обработки; заливка модельного материала вокруг сердечника в объем, превышающий объем литой детали, пространственно определяемый в трехмерной модели положением сердечника в держателе для обработки, и отверждение модельного материала; изготовление с использованием ЧПУ внешнего контура расходной модели литой детали, пространственное положение объема которой определено положением сердечника в держателе для обработки, вокруг сердечника из отвердевшего модельного материала в соответствии с трехмерной моделью в рамках второго метода изготовления с использованием ЧПУ; нанесение керамической формы на внешний ...

ПРЕСС-ФОРМА ДЛЯ ИЗГОТОВЛЕНИЯ ВЫПЛАВЛЯЕМЫХ МОДЕЛЕЙ ОТЛИВОК С ПОДНУТРЕНИЯМИ

Полезная модель относится к области литейного производства. Пресс-форма для изготовления выплавляемых моделей отливок с поднутрениями содержит соединенные верхнюю и нижнюю полуматрицы, вставки (8) и державки (3). В верхней полуматрице выполнены пазы, в которых установлены вставки (8). Державки размещены в верхней полуматрице в контакте со вставками поверхностей (6, 7) и с возможностью выдвижения и фиксации в верхней полуматрице посредством крепежных осей. Вставки выполнены с возможностью поперечного перемещения относительно выдвижения державок по опорным поверхностям верхней полуматрицы. Использование державок со вставками позволяет оформлять поднутрения (12) в сложных отливках. Обеспечивается расширение эксплуатационных возможностей при упрощении конструкции пресс-формы в условиях мелкосерийного производства. 1 з.п. ф-лы, 5 ил.

Способ удаления модельного блока из керамической формы в литье по выплавляемым моделям

Изобретение относится к области литейного производства и может быть использовано при литье по выплавляемым моделям в керамические литейные формы. Способ удаления модельного блока из керамической формы в литье по выплавляемым моделям, состоящего из воскового модельного состава, на котором сформирована керамическая форма, включает пропитку керамической формы водой, размещение ее в бойлерклаве для вытапливания модельного блока и предварительную прокалку керамической формы. Керамическую форму с модельным блоком, содержащим как минимум одну восковую модель, замачивают в воде в течение 3-5 мин, что позволяет увеличить теплопроводность форм и сократить время вытапливания форм в бойлерклаве. Вытапливают модельный блок в бойлерклаве в течение 7-9 мин. Предварительную прокалку керамической формы проводят при температуре 740-750°С в течение 3-4 ч для гарантированного удаления кристаллизационной воды и органической составляющей восков модельного блока. Обеспечивается повышение качества изготавливаемой ...

Способ получения выплавляемой модели тела вращения

Изобретение относится к области машиностроения и может быть использовано при изготовлении выплавляемой литейной модели. Способ получения выплавляемой модели тела вращения включает дозированную подачу порошка воскообразной модельной композиции в форму в виде тела вращения и вращение упомянутой формы относительно ее вертикальной оси. Воскообразная модельная композиция представляет собой порошок фракции не менее 0,4 мм. Используют форму с внутренним радиусом не менее 3 см, которую вращают с частотой 6000-15000 об/мин. Под действием центробежной силы частицы порошка модельной композиции уплотняются на внутренней поверхности формы без подведения тепла, что позволяет получить модель с требуемой шероховатостью и геометрией. Обеспечивается устранение усадки, коробления поверхности и слоистости модели, что позволяет повысить размерную и геометрическую точность отливок и физико-механические свойства оболочковых форм. 1 табл.

Способ получения удаляемой модели тела вращения

Изобретение относится к области машиностроения и может быть использовано при изготовлении выплавляемой литейной модели. Способ получения удаляемой модели тела вращения включает дозированную подачу смеси порошка воскообразной модельной композиции и гранул нитрата аммония в форму в виде тела вращения и вращение упомянутой формы относительно ее вертикальной оси. Используют форму с внутренним радиусом не менее 3 см, которую вращают с частотой 6000-15000 об/мин. Смесь порошка воскообразной модельной композиции и гранул нитрата аммония используют при следующем соотношении компонентов, мас.%: воскообразная модельная композиция фракций не менее 0,4 мм – 90-99, нитрат аммония – 1-10. Под действием центробежной силы частицы порошка модельной композиции уплотняются на внутренней поверхности формы без подведения тепла и вытесняются на внешнюю поверхность модели, заполняя участки между гранулами нитрата аммония, что позволяет получить модель с требуемой шероховатостью и геометрией. Обеспечивается устранение ...

Способ получения выплавляемой модели тела вращения

Изобретение относится к области машиностроения и может быть использовано при изготовлении выплавляемой литейной модели. Способ получения удаляемой модели тела вращения включает дозированную подачу смеси порошка воскообразной модельной композиции и воды в форму в виде тела вращения и вращение упомянутой формы относительно ее вертикальной оси. Используют форму с внутренним радиусом не менее 3 см, которую вращают с частотой 6000-15000 об/мин. Смесь порошка воскообразной модельной композиции и воды используют при следующем соотношении компонентов, мас.%: воскообразная модельная композиция фракций не менее 0,4 мм – 95-99, вода – 1-5. Под действием центробежной силы частицы порошка модельной композиции уплотняются на внутренней поверхности формы без подведения тепла и вытесняются на внешнюю поверхность модели. Вода вытесняется на внешнюю поверхность модели и создает прослойку между формой и моделью, что позволяет получить модель с требуемой шероховатостью и геометрией. Обеспечивается устранение ...

КОМПОЗИЦИЯ ЗАЛИВОЧНОГО МАТЕРИАЛА НА ГИПСОВОЙ ОСНОВЕ ДЛЯ ЛИТЬЯ И СПОСОБ ПРОИЗВОДСТВА КОМПОЗИЦИИ ЗАЛИВОЧНОГО МАТЕРИАЛА НА ГИПСОВОЙ ОСНОВЕ ДЛЯ ЛИТЬЯ

Изобретение относится к литейному производству и может быть использовано в стоматологии. Способ изготовления литейной наливной формовочной смеси быстрого разогрева в виде изделия включает получение порошкообразной композиции, средний диаметр частиц которой равен 30 мкм или менее, добавление в нее затворяющей жидкости и затворение для последующего отверждения в виде изделия в высокотемпературной печи. В качестве основных компонентов порошкообразная композиция содержит обожженный гипс, кварц и кристобалит, а также порошкообразный или низководный жидкий влагоудерживающий компонент. При приготовлении порошкообразной композиции осуществляют соизмельчение материала, состоящего из по меньшей мере одного из: обожженного гипса и кварца, обожженного гипса и кристобалита, обожженного гипса, кварца и кристобалита, а во время смешивания основных компонентов добавляют порошкообразный или низководный жидкий влагоудерживающий компонент. Обеспечивается сокращение времени выдержки для отверждения смеси в ...

Способ получения огнеупорной оболочковой формы с использованием солевых моделей

Изобретение относится к области литейного производства. Способ получения огнеупорной оболочковой формы на готовом водном связующем с использованием водорастворимых солевых моделей для литья по растворимым моделям включает нанесение покрытия на поверхности водорастворимых солевых моделей, обеспечивающего смачивание поверхности модели и предотвращающего растворение модели в водной облицовочной суспензии. Поверхности модели покрывают равномерным слоем неводорастворимой восковой массы, используемой для получения выплавляемых моделей, толщиной 0,1-0,2 мм. Используют раствор восковой модельной массы в объеме 3-10 г на 100 мл растворителя, в качестве которого используют бензин Калоша. Сушку каждого слоя производят при комнатной температуре до полного испарения растворителя. Обеспечивается высокая геометрическая точность и качество формообразующей поверхности.

Способ выплавления модельного состава горячим воздухом

Изобретение относится к литейному производству. Способ выплавления модельного состава включает нагрев оболочки с моделью горячим воздухом в два этапа. На первом этапе осуществляют кратковременный нагрев увлажненным горячим воздухом с температурой 80-90°С и влажностью 75-90%. На втором этапе нагревают сухим горячим воздухом с температурой 150-300°С до полного выплавления модельного состава. Обеспечивается получение расплавленного слоя на границе модели и оболочки за короткое время, обеспечивается свободное расширение модели и гарантированное предупреждение образования трещин в оболочке. 1 ил.

ГОЛОВКА БЛОКА ЦИЛИНДРОВ ДЛЯ ДВИГАТЕЛЯ ВНУТРЕННЕГО СГОРАНИЯ

Способ изготовления моделей из пенополистирола для получения композиционных отливок методом литья по газифицируемым моделям

ЛИТЕЙНАЯ ФОРМА

... 1. Модель (12) для литья по разовой модели, выполненная в форме лопатки газотурбинного двигателя с хвостовиком (15) и пером (14) с обеих сторон полки (20), которая, по существу, перпендикулярна основной оси лопатки, причем указанное перо лопатки (14) имеет корыто (17), спинку (16), входную кромку (18) и выходную кромку (19), причем модель (12) также включает расширительную полосу (21), смежную выходной кромке (19) и огнеупорный стержень (23), заделанный в модель (12), но имеющий как на корыте (17), так и на спинке (16) соответствующую выровненную лакированную поверхность (31) между выходной кромкой (19) и расширительной полосой (21), отличающаяся тем, что она также включает перегородку (24), продолжающуюся между полкой (20) и указанной расширительной полосой (21) и имеющую свободную кромку (25) между ними.2. Модель (12) по п. 1, в которой свободная кромка (25) перегородки (24) продолжается от одного края (26) полки (20) до расширительной полосы (21).3. Модель (12) по п. 1, имеющая последовательный ...

Verfahren zur Herstellung keramischer Giessmasken zum Giessen mit verlorenem Modell

Producing a workpiece prototype

The method consists of a repeated sequence of the following steps: (a) application of a thin layer (13) consisting of a mould material, with cutouts (14) corresponding to the workpiece geometry, onto a carrier structure (18); and (b) filling of the cutouts with a castable workpiece material (16). The mould material is removed after a required number of repetitions of the above two steps. Alternatively thin layers of a workpiece material is applied onto a carrier structure. The layers are provided with contour lines and cutouts or grooves which subsequently are filled with a mould material. After a required number of repetitions of these steps the mould material is removed.

Werkstoffe fuer Praezisionsgussmodelle

Verfahren zur Herstellung eines thermisch belasteten Gussteils

Zur Herstellung eines thermisch hoch belasteten Gussteils (1, 14, 16, 17) einer thermisch Turbomaschine, welches mit einem bekannten Gussverfahren hergestellt wird, wird die Gussform aus einem Schlicker mit einem Wachsmodell und einem daran angehefteten oder in einen Hohlraum eingeführten Polymerschaum hergestellt. Auf diese Weise dringt während des Gussverfahrens die flüssige Superlegierung auch in die offenporige Struktur der Gussform ein, so dass eine integrale Kühlstruktur (7) während des Erstarrungsvorgangs des Gussteils (1, 14, 16, 17) entsteht. Vorteilhaft wird ein einkristallines oder gerichtet erstarrtes Gussteil (1, 14, 16, 17) hergestellt. Auch eine Variation der Porengröße des Polymerschaums, eine getrennte Herstellung von Kühlstruktur (7) und Grundwerkstoff und eine Beschichtung der Kühlstruktur (7) mit einer keramischen Schutzschicht (TBC) (11) ist denkbar.

Verfahren zur Herstellung eines Bauteils, Bauteil und Turbomaschine mit Bauteil

Die Erfindung betrifft ein Verfahren zur Herstellung eines metallischen Bauteils (10) besonders eingerichtet und ausgebildet für eine Turbomaschine (100), wobei a) für ein Feingussverfahren ein Wachsmodell (20) mit einer Wachsstruktur (21) hergestellt wird, anschließend b) die Spitze (23) der Wachsstruktur (21) thermisch und/oder mechanisch behandelt wird, so dass sich an der Wachsstruktur (21) ein Bereich mit einer Hinterschneidung (22) bildet, anschließend c) im Feingussverfahren aus dem Wachsmodell (20) das metallische Bauteil (10) hergestellt wird, wobei auf einer Oberfläche des Bauteils (10) ein Bauteilstrukturelement (11) mit Hinterschneidung (12) entsteht, d) das Bauteilstrukturelement (11) mindestens teilweise mit einer keramischen Beschichtung (2) versehen wird. Ferner betrifft die Erfindung ein Bauteil, herstellbar mit diesem Verfahren sowie Verwendungen in Turbomaschinen.

Laserunterstütztes Gießen eines Kühllochs und zugeöhrigen System

Verschiedene Ausführungsformen umfassen Verfahren und zugehörige Systeme für laserunterstütztes Gießen. Einige Ausführungsformen umfassen ein Verfahren, das aufweist: Durchführen einer Laserablation an einem vorläufigen Wachsgussmodell zur Ausbildung eines modifizierten Wachsmodells, das wenigstens ein Kühlloch aufweist, das in dem Wachsgusssubstrat fehlt; Beschichten des modifizierten Wachsmodells, um eine Gussformgestalt um das modifizierte Wachsmodel herum auszubilden; und Entfernen des modifizierten Wachsmodells, um eine Gussform zu hinterlassen, die das wenigstens eine Kühlloch aufweist.

Formsystem mit trennbaren, variablen Formteilen zur Bildung eines Gussgegenstands für den Feinguss

Es sind ein Formsystem (100, 200) und ein Verfahren zur Bildung eines Gussgegenstandes (102) für den Feinguss offenbart. Das Formsystem (100, 200) enthält eine Form (110, 210) zur Aufnahme eines ausgewählten Kerns (112, 112A, 112B) darin, der aus mehreren unterschiedlichen Kernen (112, 112A, 112B) ausgewählt wird. Die Form (110, 210) enthält mehrere trennbare Formteile (120A-F), die miteinander verbindbar sind, um die Form (110, 210) zu erzeugen, und eingerichtet sind, um ein Opfermaterial (130) aus einem Opfermaterialfluid um den ausgewählten Kern (112, 112A, 112B) zu bilden. Wenigstens ein ausgewählter trennbarer Formteil (120A-F) der mehreren trennbaren Formteile (120A-F) enthält einen Satz unterschiedlicher austauschbarer Varianten des wenigstens einen ausgewählten trennbaren Formteils (120A-F, 120K-N). Jede unterschiedliche austauschbare Variante des ausgewählten trennbaren Formteils (120A-F, 120K-N) ist eingerichtet, um einen anderen Kern (112, 112A, 112B) der mehreren unterschiedlichen ...

Verfahren zur Herstellung eines Gussstücks mit verbesserter Wärmeübertragungsfläche und Wachsmodell zu ihrer Herstellung

Genauguss

HALTER FUER EIN IN EINER SPRITZGUSSFORM HERGESTELLTES WACHSMODELL

VERBESSERUNGEN BEIM FEINGIESSEN

Production of shell moulds

... 948,197. Refractory shell moulds. MONSANTO CHEMICALS Ltd. June 26, 1962 [July 20, 1961], No. 26283/61. Heading B5A. A wax pattern for the production of a shell mould is coated with a slurry containing a powdered refractory. After the layer has dried the coated pattern is exposed to steam under pressure in order to melt the wax. Microcrystalline or carnauba wax can be used. The refractory materials aluminosilicates, silicon carbide, oxides such as silica, alumina, magnesia or zirconia and various calcined fireclays can be used, preferably with a silica containing binder.

Ceramic core with locators and method

Improvements in or relating to models or replicas for use in the cire-perdue casting process

In a "cire-perdue" casting process a mixture containing at least 50 per cent paraffin wax and 7 to 50 per cent polyethylene is melted and cast by gravity or pressure to form the model to be invested. A wax of M.P. 50-62 DEG C. and polyethylene of M.P. 170 DEG C. may be used and fatty substances, aromatic hydrocarbons, synthetic and natural waxes, e.g. carnauba, and resins may be included in an amount up to 8 per cent of the mixture.

Process for the production of heat exchanger tubes consisting of half-tubes or tubes, for recuperative waste gas heat exchangers

Soluble Cores

... 1,184,897. Soluble mould-cores. WELLWORTHY Ltd. 6 June, 1967 [6 June, 1966], No.25169/66. Heading C3N. A soluble core for metal-casting comprises sodium silicate mixed with NaCl or Na 2 SO 4 blown or rammed into a core-box; the sodium silicate is gelled, and the core hardened by baking. The gelling may be done by gassing with CO 2 . The core-box may be preheated, e.g. to 100-180‹ C. and the baking may be performed, e.g. at 100-180‹ C, with the core still in, or having been removed from, the corebox. The core-box may be of wood or, if to be heated, of metal. The NaCl or Na 2 SO 4 may be in granular form, preferred sieve analyses being given. The mixture may comprise 3-10% wt. of sodium silicate. The mixture may also include 0-5% ground silica gel, or 2-12% kaolin. Metal wires may be incorporated.

Medical prosthesis implant casting process

METHOD OF PRODUCING RESIN ARTICLES USING A PLASTER MOULD

Method of investment casting with casting identification

Method of making an object having an internal lattice-type structure

A method of making a structure by stereolithography comprises producing a structure comprising sets of parallel plates 13,15,17 in three different levels in a repeating pattern, with each set of plates in an adjacent level rotated through 120{ such that in plan view the plates define a plurality of hexagonal formations. The structure may be provided with an outer skin and may be used to form a mould in a method in which the structure is coated, for example, with a ceramic material, after which the structure is removed, for example by burning out, to leave a mould into which a mouldable material may be cast.

Investment moulding process and apparatus

Filler material and wax composition for use in investment casting

Cores for lost wax casting.

A wax pattern used in the lost wax process is restrained from movement with respect of an adjacent ceramic core by an aperture in the core which becomes filled with wax during the wax injection; the aperture being shaped such as to prevent removal of the wax therefrom after solidification.

LOST WAX PATTERNS

Investment casting process and mould

In the investment casting of hollow parts in a shell mould or in a block mould a slender core (2) is supported by means of chaplets (7) in an outer mould part (1). The chaplets are made of expanded metal and are preferably bent to form a 'C', 'V' or 'U' shaped cross section. This form of chaplet provides for good support whilst promoting diffusion thereof during the casting of the molten metal in the mould.

Water soluble polymeric material

A water-soluble pattern material for use in investment casting comprises a water-soluble polymer, such as a polyethylene glycol wax, and a dissolution accelerant including or comprising an acid which, on contact with an aqueous leaching agent, reacts with a carbonate or bicarbonate, either in the polymer or in the leaching agent, to produce effervescence which breaks up and promotes the dissolution of the polymer. The formulation may also incorporate a filler which is preferably water-soluble.

Laser assisted casting of a cooling hole

Improvements in or relating to pattern composition for a "lost wax" casting process

Pattern compositions suitable for use in the "Lost Wax" casting process, comprise hydrocarbon wax as the major component, e.g. 50-70%, with minor proportions of polyethylene of M.W. not more than 6000, e.g. 5-25%, and a cyclic hydrocarbon synthetic resin plastisizer, e.g. 10-40%. The wax is preferably a high melting-point, e.g. 80-84 DEG C., microcrystalline wax, and/or one or more paraffin or synthetic hydrocarbon waxes such as Fischer Tropsch waxes. The resin may be derived from b -pinene, alkyl styrene or indene, or may be mixtures thereof. In an example the composition comprises 60% microcrystalline wax, 10% polyethylene and 30% b -pinene resin.

Method for processing an additively manufactured investment casting model

Single crystal casting

Improvements relating to casting processes for metals

... 789,722. Making moulds for metal-casting; refractory compositions. ROLLS-ROYCE, Ltd. March 9, 1955 [March 9, 1954], No. 36593/54. Divided out of 789,721. Class 87(2). [Also in Group XXII] Relates to a refractory insert or core which is to form part of a pattern for use in making a metalcasting mould, the core remaining in the mould after removal of wax &c. constituent of the pattern and serving to form a hollow in the metal article (e.g., turbine blade) being made. According to the invention the insert or core is made by investing a strengthening member of silica or alumina with a slurry comprising sillimanite and acid hydrolysed ethyl silicate. Thus the core may be made by casting the slurry 11, Fig. 1, in a mould A, B, around rods 10 made of silica or alumina. The rods may be hollow. A suitable slurry is described, comprising ethyl silicate, hydrochloric acid, methylated spirits, ammonia and light magnesia which gels the slurry. The cast core is then removed from the mould and the alcohol ...

Method and apparatus for producing casting shell

A ceramic casting shell is formed by a method comprising the steps of coating a wax former with one or more layers of a ceramic slurry; drying the or each layer of ceramic slurry; wherein the dried layer or layers of ceramic slurry form a ceramic shell; applying over the ceramic shell a coating of a polymer material; heating the formed assembly to melt and remove the wax former, wherein the polymer coating acts as a strengthening layer to the ceramic shell during the wax removal process; and subsequent removal of the wax former, heating the ceramic shell to melt and remove the polymer coating. The polymer coating is preferably the outer coating of the ceramic shell. The polymer may be polyvinyl alcohol, styrene butadiene, an acrylic polymer, an epoxy resin, a latex, or any combination thereof. The polymer coating preferably has low amounts or is free of refractory material, and preferably only comprises polymeric material. The polymer coating may be applied by spraying, dipping, or painting ...

DEVICE AND PROCEDURE FOR MANUFACTURING A CASTING BODY FOR THE USE WITH THE DETAILS CASTING

REFRAKTÄRMETALLKERN

ONE-PIECE LOSING, KEEP AT A MODERATE TEMPERATURE-CASH MOLD FOR CAST PARTS MADE OF METAL AS WELL AS PROCEDURES FOR YOUR PRODUCTION

PROCEDURE FOR THE PRODUCTION OF A MUFFEL FOR FEINODER MODEL CASTING AS WELL AS COMPOSITION TO THEIR PRODUCTION

HIGH QUALITY CASTING NUCLEAR ARRANGEMENT

HOLLOW, METALLIC GULF RACQUET HEAD AND ITS PRODUCTION

Brechkern for the sand form casting, in particular for iron and cast steel, and procedure for its production

DEVICE AND PROCEDURE FOR THE INVESTMENT CASTING OF SHAPED PARTS FROM WAX

Procedure for manufacturing lost models for the precision casting process

Improvements in investment casting

Treatment of thermoplastic materials with chelating agents, and related products

Process for the manufacturing of molds

Gauge face inlay for bit hardfacing

WAX INJECTION NOZZLE WITH RELIEF RESERVOIR

PATTERN MATERIAL COMPOSITION

PRODUCING VERY LIGHT WEIGHT CAST METAL JEWELRY RINGS THAT FEATURE A CLOSED HOLLOW ASPECT

This invention relates to a method for the production of master patterns for the jewelry industry, producing the required molds for the duplication of the form and details of the master patterns in a very thin vacuum formed thermoplastic sheeting that are then cast in metal using the well documented 'lost wax process'.

GYPSUM-BASED INVESTMENT MATERIAL COMPOSITION FOR CASTING, AND METHOD FOR MANUFACTURING GYPSUM-BASED INVESTMENT MATERIAL COMPOSITION FOR CASTING

To provide a gypsum-based investment material composition for casting and a method for manufacturing the same, the investment material composition being useful as a flash-heating-type gypsum-based investment material for making it possible to provide a product in which exposure time is reduced, such reduced exposure time not having been realized in the conventional product. A gypsum-based investment material composition for casting and a method for manufacturing the same, the investment material composition being a gypsum-based powdery investment material composition for casting, for use as a flash-heating-type investment material to which a malaxation liquid is added, the mixture is cured after malaxation, and the cured product is placed in a high-temperature furnace, wherein the gypsum-based investment material composition for casting has calcined gypsum, quartz, and cristobalite as main components thereof, the gypsum-based investment material composition for casting includes a powder ...

SINGLE CRYSTAL CASTING MOLD AND METHOD FOR MAKING SAME

METHOD OF MAKING A UNITARY PATTERN ASSEMBLY

CASTING WITH METAL COMPONENTS AND METAL SKIN LAYERS

The present disclosure generally relates to casting molds including a casting core comprising an outer shell mold surrounding at least a portion of a casting core and a casting core comprising a second metal skin layer around a first metal component. In one aspect, at least one portion of the first metal component may be exposed on a surface of the outer shell mold. In another aspect, the outer shell mold may be configured to define a cavity in the casting core when the first metal component is removed and the second metal skin layer is not removed.

CASTING WITH FIRST METAL COMPONENTS AND SECOND METAL COMPONENTS

The present disclosure generally relates to casting molds including a casting core comprising a first metal component and a second metal component. In an aspect, the first metal component has a lower melting point than the second metal component. In another aspect, the second metal component surrounds at least a portion of the first metal component and defines a cavity in the casting core when the first metal component is removed and the second metal component is not removed.

MOLD AND FACECOAT COMPOSITIONS AND METHODS FOR CASTING TITANIUM AND TITANIUM ALUMINIDE ALLOYS

The disclosure relates generally to mold compositions and methods of molding and the articles so molded. More specifically, the disclosure relates to mold compositions, intrinsic facecoat compositions, and methods for casting titanium-containing articles, and the titanium-containing articles so molded.

METHOD OF CONSTRUCTING FULLY DENSE METAL MOLDS AND PARTS

A method of constructing a fully dense metal part or a metal mold half for mating with another mold half to form a mold for casting multiple parts. Steps include placing a pattern having critical pattern surfaces in a flask having an open end. The critical pattern surfaces face upward. Other steps involve covering the critical pattern surfaces with a concentrated heat reversible gel solution added to the flask, and cooling the gel solution to form an elastic solid gel mold. Further steps include removing the flask and the pattern from the elastic gel mold, and casting a ceramic mold around the solid gel mold. In other steps the gel mold is liquified for removal from the ceramic mold and the ceramic mold is inverted so that its critical ceramic surfaces face upward. Still other steps involve covering the critical ceramic surfaces with a powder, and placing a quantity of an infiltration material over the powder, and placing the ceramic mold, the powder, and the infiltration material in a ...

Verfahren zur Herstellung von Hohlräumen im Innern von Gussstücken.

Material zur Herstellung verlorener Modelle bei der Herstellung von Giessformen für zahntechnische Artikel.

Modèle creux pour fonderie et procédé de fabrication de ce modèle.

Procédé pour la confection de moules réfractaires et modèle pour la mise en oeuvre du procédé.

Procédé de moulage d'un objet creux.

Composition thermo-plastique.

Modèle pour la fabrication de moules réfractaires.

Giessverfahren, insbesondere für Metalle und Metallegierungen.

Verfahren und Einrichtung zur Herstellung von Präzisionsgussformen

Verfahren zur Herstellung von Giessereimodellen

Verfahren zur Herstellung einer Gussform und Modell zur Ausführung dieses Verfahrens.

Verfahren zur Herstellung von Giesslingen aus Kunstharz.

Verfahren zur Herstellung hohler, ausschmelzbarer Modelle für Gusszwecke.

Matrize zur Herstellung von für den Guss nach dem Wachsausschmelzverfahren dienenden Wachsmodellen

Verfahren zur Herstellung von harten, elastischen Wachsgrundstoffen mit geringem Schwund und Verwendung dieser Wachsgrundstoffe zur Herstellung von Modellwachsen

Verfahren zum Herstellen von verlorenen Modellen für das Präzisionsgiessverfahren

Verfahren zur Herstellung von Wachsmodellen für das Präzisionsgiessverfahren.

Verfahren zur Herstellung von Giessformen.

Mélange pour la formation de modèles dans le moulage à cire perdue.

Verfahren und Vorrichtung zur Herstellung von Wachsmodellen zum Präzisionsgiessen mit einem verlorenen Wachsmodell sowie nach diesem Verfahren hergestelltes Wachsmodell

Gussform für Wachsmodellguss

Foam patterns

A method of creating a foam pattern comprises mixing a polyol component and an isocyanate component to form a liquid mixture. The method further comprises placing a temporary core having a shape corresponding to a desired internal feature in a cavity of a mold and inserting the mixture into the cavity of the mold so that the mixture surrounds a portion of the temporary core. The method optionally further comprises using supporting pins made of foam to support the core in the mold cavity, with such pins becoming integral part of the pattern material simplifying subsequent processing. The method further comprises waiting for a predetermined time sufficient for a reaction from the mixture to form a foam pattern structure corresponding to the cavity of the mold, wherein the foam pattern structure encloses a portion of the temporary core and removing the temporary core from the pattern independent of chemical leaching.

Methods for forming faucets and fixtures

This invention provides methods for forming stainless steel, single-piece, multi-chambered water faucets and fixtures with a single one-body construction. A variety of stainless steel products can be formed with a main body having an internal hollow region and a plurality of dividing chambers. The main body may be constructed using high temperature resistant ceramic cores in combination with a lost wax investment casting process. The stainless steel products formed from a single piece construction can eliminate the need for additional time-consuming manufacturing steps, such as parts welding, screw assembly, or precision press fitting. In addition, water faucets and fixtures can be provided that are substantially lead-free, non-verdigris, and non-toxic in compliance with environmental regulations and lead/toxic limits.

Method and apparatus for creating a pattern

A method and apparatus for creating a pattern of an item of manufacture, the method and apparatus including the use of a mold frame, mold, mold core, injection frame and injection core to create patterns of items of manufacture for investment casting.

One-piece manufacturing process

A method of making a turbomachine part, wherein the method can include machining a blank into a base having blades extending therefrom, the blades defining a channel therebetween. The method can also include forming a bridge constructed from refractory material in the channel between the blades, and forming a cover on the tops of the blades and over the channel, such that the base, the blades, and the cover form a single substantially homogenous turbomachine part once the bridge is removed.

FOAM PATTERN TECHNIQUES

Various techniques are provided for creating fugitive foam patterns for use in investment casting operations. In certain illustrative embodiments, a fugitive foam pattern is assembled from independently formed portions. A first section is formed in a mold. Once cured, a mating surface of the first section is exposed to the cavity of a second mold and the section is formed. The second section integrally adheres to the first section. The process is repeated as necessary. In alternative embodiments, a channel is created in a foam pattern using a temporary core that is removed without chemical leaching. The core material comprises water-soluble materials, acid-soluble materials, low-melting point materials, or a combination thereof. A pattern may also be created by inserting foam around a core that remains with the foam pattern. 1. A method of assembling a fugitive foam pattern , the method comprising:inserting a mixture comprising polyol and isocyanate into a mold cavity of a first mold corresponding to a first portion the foam pattern;waiting for a predetermined time sufficient for a first reaction from the mixture to form a foam pattern structure corresponding to the first portion of the foam pattern, wherein the first portion includes a mating surface;exposing the mating surface of the first portion of the foam pattern structure to a mold cavity of a second mold corresponding to a second portion of the foam pattern;inserting the mixture into the mold cavity of the second mold corresponding to the second portion the foam pattern; andwaiting for a predetermined time sufficient for a second reaction from the mixture to form a foam pattern structure corresponding to the second portion of the foam pattern such that the second reaction bonds the second portion to the mating surface of the first portion of the foam pattern structure.2. The method of claim 1 , wherein exposing the mating surface of the first portion comprises removing the foam pattern structure ...

MOULD FOR PRODUCING PARTS BY WAX INJECTION

A mold for producing a part, such as a turbomachine blade model, by injecting wax into a cavity, the cavity including at least two cavity elements, each of which is supported in a cavity block. The two cavity blocks are mobile relative to one another between a closed position for injecting the wax and an open position for removing the part following the injection of the wax. The two cavity blocks are mobile in a horizontal plane. 17-. (canceled)8. A mold for producing a turbomachine blade model , comprising:a cavity into which wax can be injected, the cavity including at least two cavity elements forming respectively at least an intrados face and an extrados face of a blade of a turbomachine and each supported in a cavity block, the two cavity blocks being mobile relative to one other in a horizontal movement plane between a closed position for injecting the wax and an open position for removing a part following injection of the wax, by being driven by a means for setting into motion, or a manual means or a motor,wherein the means for setting into motion comprises a fixed plate forming a base for the cavity blocks, a plate that is mobile in translation relative to the base plate, through a transmission means to the mobile plate of efforts made by the manual means or motor, and a mechanism by which relative displacement between the mobile plate and the fixed plate drives that of the cavity blocks.9. The mold as claimed in claim 8 , wherein the mechanism comprises lugs claim 8 , each being integral with a cavity block and being guided in slots arranged in the fixed base plate and slots arranged in the plate that is mobile in translation relative to the base plate claim 8 , the displacement of the mobile plate driving that of the blocks by the lugs.10. The mold as claimed in claim 8 , wherein the cavity blocks are mobile in a circular arc.11. The mold as claimed in claim 8 , including a third cavity element supported in a cavity block that is mobile in relation to the ...

INJECTION MOLD FOR A WAX MODEL OF A TURBINE BLADE HAVING AN ISOSTATIC CORE HOLDER

The invention relates to an injection mold for producing a model of a turbine engine blade, comprising a top surface that folds onto a bottom surface, both surfaces having long rods for supporting a core () for generating cooling cavities inside the blade, wherein said long rods of the bottom surface are to contact a first surface () of the airfoil at bearing points (A to A), and said long rods of the top surface are to contact a second surface of said airfoil at clamping points. The injection mold is characterized in that it also comprises at least one short rod (TF to TF TF to TF) extending from one of the surfaces of the mold and pointing towards a false point (F to F, F to F) located on one of the surfaces () of the airfoil (2), the length of the short rod being shorter than the distance between the surface of the mold and the surface of the blade at the aforementioned false point, and the difference between said length and said distance being equal to the tolerance in relation to the positioning of the false point in the event of a deformation of the core. 1515351532222515312251535153225153babb. An injection mold for producing a model of a turbine engine blade to be produced by the lost wax casting technique , comprising an upper face which folds onto a lower face , the two faces having a footprint reproducing the external shape of the blade to be produced and carrying long rods (TA to TA , TS to TS) for supporting a core () designed to generate cooling cavities inside the blade , said core having the shape of an aerofoil () between a root () and a tip () , said long rods of the lower face (TA to TA) being designed to come into contact with a first face () of the aerofoil () in the region of bearing points (A to A) and said long rods of the upper face (TS to TS) being designed to come into contact with a second face () of said aerofoil in the region of clamping points (S to S) , each clamping point of the second face being positioned opposite a bearing point of ...

EVAPORATIVE PATTERN FOR CASTING AND CASTED PRODUCT

An evaporative pattern having a high strength is provided. An evaporative pattern is a pattern for an evaporative casting. In the evaporative pattern a reinforcing member which is made of a non-evaporative material that does not evaporate by heat of a molten metal is embedded in a joint which is made of an evaporative material that evaporates by the heat of the molten metal. The evaporative material is typically foam polystyrene. The strength of the foam polystyrene is low. Since the reinforcing member which is made of a material having strength higher than that of the evaporative material is embedded in the evaporative pattern which is made of the foam polystyrene, the strength of the evaporative pattern improves. 1. An evaporative pattern for casting , wherein a reinforcing member made of a non-evaporative material that does not evaporate by heat of a molten metal is embedded in the evaporative pattern made of an evaporative material that evaporates by the heat of the molten metal; anda wire extends from the reinforcing member to outside of the evaporative pattern.2. The evaporative pattern of claim 1 , wherein the entire reinforcing member is covered by the evaporative material.3. A casted product made by a casting using the evaporative pattern of claim 1 , wherein the reinforcing member made of a metal that is different from a casting material is embedded in the casted product.4. The casted product of claim 3 , wherein the casted product includes a plurality of rod members that configures a frame configured by any one of a Rahmen structure claim 3 , a truss structure claim 3 , and a combination structure of the Rahmen structure and the truss structure claim 3 , and the reinforcing member is embedded at a joint of the frame.5. A casted product made by a casting using an evaporative pattern claim 3 , wherein:the evaporative pattern includes a reinforcing member embedded therein, the reinforcing member being made of a non-evaporative material that does not ...

SET OF MEMBERS FOR AN EVAPORATIVE PATTERN AND AN EVAPORATIVE PATTERN

A lightweight metal mold having a necessary hardness is realized. A plurality of bar-shaped members formed of an evaporative material and a plurality of connecting members formed of an evaporative material are prepared. Each of the connecting members has a spherical shape, and ends of a plurality of the bar-shaped members can be connected to each connecting member. Since a fixing angle of each bar-shaped member with respect to the connecting member can be adjusted freely, a three-dimensional mesh structure having various shapes can be formed. By combining the plurality of bar-shaped members and the plurality of connecting members, an evaporative pattern including the three-dimensional mesh structure can be assembled. By adjusting the shape of the three-dimensional mesh structure, the hardness necessary for the metal mold can be obtained, and the metal mold can be made lighter. 1. An evaporative pattern to be used in a full-mold casting , the evaporative pattern being assembled of a plurality of bar-shaped members formed of an evaporative material and a plurality of connecting members formed of an evaporative material , whereineach of the connecting members has a spherical shape, andends of a plurality of the bar-shaped members are connected to each connecting member to form a three-dimensional mesh structure.2. A set of members for assembling an evaporative pattern to be used in a full-mold casting , the set including:a plurality of bar-shaped members formed of an evaporative material; anda plurality of connecting members formed of an evaporative material, whereineach of the connecting members has a spherical shape,ends of a plurality of the bar-shaped members can be connected to each connecting member, anda fixing angle of each bar-shaped member with respect to the connecting member can be adjusted freely.3. The set of claim 2 , wherein a projection that lodges on the connecting member is formed at the end of each bar-shaped member. The present invention relates to ...

Evaporative pattern, method of forming an evaporative pattern, and method of forming a metal mold by using an evaporative pattern

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. The metal mold is made lighter by using the three-dimensional mesh structure. Due to the replacement with the tube member, an amount of gas generated upon the full-mold casting is suppressed, and a decrease in casting quality is prevented.

Turbocompressor rotor and method for producing the same

A turbocompressor rotor for a turbocompressor for compressing process gas has a rotor body which makes contact with the process gas and which is produced entirely from a stainless steel material including 0.3 to 1.2% carbon and 12 to 19% chromium, wherein the steel material includes the alloy X39CrMo17-1.9. A process for producing such a turbocompressor rotor by casting includes manufacturing a casting model corresponding to the geometry of the rotor body by rapid technology and producing a casting mold using the casting model, or manufacturing a casting mold corresponding to the negative geometry of the rotor body by rapid technology, introducing the liquid steel material into the casting mold to form a cast workpiece as the rotor body, and finishing the turbocompressor rotor with the rotor body.

INVESTMENT CASTING UTILIZING FLEXIBLE WAX PATTERN TOOL FOR SUPPORTING A CERAMIC CORE ALONG ITS LENGTH DURING WAX INJECTION

An investment casting process wherein the wax pattern tool () is flexible to provide compliant support for an enclosed ceramic core () and to facilitate removal of the tool from the cast wax pattern () even when the cast shape would otherwise require multiple pull planes. Positioning pins () may extend from the flexible tool to make compliant contact against the core during the wax injection step. The pins may cooperate with a pedestal () formed on the core to support the core along multiple axes during wax injection, thereby allowing a higher wax injection pressure without damage to the core. 1. A method of producing a wax pattern for an investment casting process , the method comprising:positioning a ceramic core within a wax pattern mold;supporting the ceramic core from a flexible surface of the mold;injecting melted wax into the mold around the ceramic core; andremoving the mold after the wax has hardened to reveal the ceramic core encased inside a wax pattern.2. The method of claim 1 , further comprising injecting the melted wax at a pressure of greater than 175 psig.3. The method of claim 1 , further comprising supporting the ceramic core at a plurality of locations along its length during the step of injecting melted wax by locating a respective plurality of pins to extend from the flexible surface of the mold to make proximate contact with the core along a respective plurality of non-parallel axes.4. The method of claim 1 , further comprising supporting the ceramic core at a location along its length during the step of injecting melted wax by locating a pin to extend from the flexible surface of the mold to make proximate contact with the core.5. The method of claim 4 , further comprising aligning the pin to make proximate contact with a pedestal formed on the core to provide support for the core along a plurality of axes.6. The method of claim 5 , further comprising forming the pedestal to have an opening defined by sloping walls for receiving the pin.7. ...

Method for digital manufacturing of jewelry items

A method for digital manufacturing of a jewelry item includes printing a three-dimensional wax model on a substrate and printing a three-dimensional sprue, the sprue being adapted to support the wax model. A fixture for handling wax models includes a platform, a plurality of holders, a plurality of standoffs, and a tie. A method of manufacturing a jewelry item, comprises forming a first wax model for a portion of a jewelry item, forming a second wax model for a portion of a jewelry item using a rapid prototyping process, and performing one or more lost wax processes with the first and second portion to create the jewelry item.

Casting of thin wall hollow airfoil sections

A casting mold assembly comprises an airfoil defining section and a casting core. The airfoil defining section includes an outer mold wall and a direct-shelled inner mold wall. The direct-shelled inner mold wall is disposed within a forward chordwise portion of the airfoil defining section. The direct-shelled inner mold wall includes an aft end having an external radius measuring more than about 0.075 in. (1.9 mm). The casting core is secured within an aft chordwise portion of the airfoil defining section, and includes an aft end with an external radius measuring less than about 0.075 in. (1.9 mm). A cast component and a method for making the casting mold assembly are also disclosed.

Three-dimensional printing of investment casting patterns

A system and method for generating investment casting patterns by 3D printing. CAD software is used to generate a hollow 3D model of a solid 3D model of a desired pattern. The pattern is generated by a 3D printer which prints the exterior of the pattern in pattern wax and the interior in support wax.

ADDITIVELY MANUFACTURED INTERLOCKING CASTING CORE STRUCTURE WITH CERAMIC SHELL

The present disclosure relates to a method of forming a cast component and a method of forming a casting mold. The method is performed by connecting at least one wax gate component to a ceramic core-shell mold. The ceramic core-shell mold includes at least a first core portion, a first shell portion, and a second shell portion, wherein the first shell portion is adapted to interface with at least the second shell portion to form at least one first cavity between the core portion and the first and second shell portions. The core-shell mold may be inspected and assembled prior to connection of the wax gate component. At least a portion of the ceramic core-shell mold and the wax gate component is coated with a second ceramic material. The wax gate component is then removed to form a second cavity in fluid communication with the first cavity. 1. A method of fabricating a ceramic casting mold comprising the steps of: a first core portion;', 'a first shell portion; and', 'a second shell portion, wherein the first shell portion is adapted to interface with at least the second shell portion to form at least a portion of a first cavity between the core portion and the first and second shell portions;, '(a) connecting at least one wax component to a ceramic core-shell mold, the ceramic core-shell mold comprising at least(b) applying a second ceramic material to coat at least a portion of the ceramic core-shell mold and the wax component with the second ceramic material; and(c) removing the wax component to form at least a second cavity in fluid communication with the first cavity.2. The method for fabricating a ceramic casting mold of claim 1 , wherein the core-shell mold is formed by:(i) contacting a cured portion of a workpiece with a liquid ceramic photopolymer;(ii) irradiating a portion of the liquid ceramic photopolymer adjacent to the cured portion through a window contacting the liquid ceramic photopolymer;(iii) removing the workpiece from the uncured liquid ceramic ...

GAS TURBINE COMPONENT WITH COOLING APERTURE HAVING SHAPED INLET AND METHOD OF FORMING THE SAME

A method of manufacturing a cooled gas turbine component includes forming a core with an outer surface. The outer surface includes a core feature. The method also includes casting an outer wall of an airfoil about the core. The outer wall has an exterior surface and an interior surface. The interior surface includes a shaped inlet portion that corresponds to the core feature. Moreover, the method includes forming an outlet portion through the outer wall to fluidly connect the outlet portion to the shaped inlet portion. The shaped inlet portion and the outlet portion cooperatively define a cooling aperture through the outer wall. 1. A method of manufacturing a cooled gas component for a turbomachine , the method comprising:forming a core with an outer surface, the outer surface including a core feature that tapers to reduce in width as the core feature projects from the core;casting an outer wall about the core including casting a portion of the outer wall that covers the core feature, the portion including an exterior surface and an interior surface, the interior surface defining a shaped inlet portion that is cast to inversely correspond to the core feature; andafter casting the outer wall, forming an outlet portion through the outer wall by progressively removing material through the portion of the outer wall in a direction from the exterior surface toward the interior surface and toward the shaped inlet portion to fluidly connect the outlet portion to the shaped inlet portion, the shaped inlet portion and the outlet portion cooperatively defining a cooling aperture through the outer wall.2. The method of claim 1 , further comprising adjusting the outlet portion by changing a dimension of the outlet portion.3. The method of claim 1 , further comprising:re-casting the outer wall; andforming an adjusted outlet portion through the re-cast outer wall.4. The method of claim 3 , wherein forming the outlet portion through the outer wall includes forming the outlet ...

EXPANDABLE METHYL METHACRYLATE RESIN PARTICLES, METHYL METHACRYLATE RESIN PRE-EXPANDED PARTICLES, METHYL METHACRYLATE EXPANSION-MOLDED BODY, AND METHOD FOR PRODUCING EXPANDABLE METHYL METHACRYLATE RESIN PARTICLES

Expandable methyl methacrylate resin particles having a narrow particle size distribution, a good yield, and excellent expandability and formability are provided. The expandable methyl methacrylate resin particles include a base resin containing, as constitutional units, a certain amount of a methyl methacrylate unit and a certain amount of acrylic ester unit, and a blowing agent. The expandable methyl methacrylate resin particles have an average particle diameter of 0.6 mm to 1.0 mm and a particle diameter variation coefficient of not more than 20%. 1. Expandable methyl methacrylate resin particles comprising:a base resin including, as constitutional units, a methyl methacrylate unit and an acrylic ester unit; anda blowing agent,a content of the methyl methacrylate unit being not less than 91 parts by weight and not more than 99 parts by weight and a content of the acrylic ester unit being not less than 1 part by weight and not more than 9 parts by weight, relative to 100 parts by weight of a total content of the methyl methacrylate unit and the acrylic ester unit in the base resin,the expandable methyl methacrylate resin particles having (a) an average particle diameter of 0.6 mm to 1.0 mm and (b) a particle diameter variation coefficient of not more than 20%.2. The expandable methyl methacrylate resin particles as set forth in claim 1 , whereinthe acrylic ester unit is a butyl acrylate unit.3. The expandable methyl methacrylate resin particles as set forth in claim 2 , whereinthe content of the methyl methacrylate unit is not less than 94 parts by weight and not more than 96 parts by weight and a content of the butyl acrylate unit is not less than 4 parts by weight and not more than 6 parts by weight, relative to 100 parts by weight of a total content of the methyl methacrylate unit and the butyl acrylate unit in the base resin, and{'sup': '2', 'an expansion-molded body obtained by pre-expanding and molding the expandable methyl methacrylate resin particles has a ...

METHOD FOR INORGANIC BINDER CASTINGS

A method for inorganic binder casting including selecting a shape-forming material based on pre-determined manufacturing and shape characteristics, forming the shape-forming material by printing the shape-forming material using a plurality of additive material printers to form a casting mold, creating a liquid binder solution, the liquid binder solution configured to include at least 51% inorganic binder material by weight, the inorganic binder material having a weight ratio to the liquid binder solution between a range of 1.0 and 3.5, coating the shape-forming material with the liquid binder solution, substantially dehydrating the shape-forming material, pouring a hot liquid metal into the casting mold, and allowing said hot liquid metal to cool to form a molded part. 1. A method for inorganic binder casting , comprising:selecting a shape-forming material based on pre-determined manufacturing and shape characteristics;forming the shape-forming material by printing the shape-forming material using a plurality of additive material printers to form a casting mold;creating a liquid binder solution, the liquid binder solution configured to include at least 51% inorganic binder material by weight, the inorganic binder material having a weight ratio to the liquid binder solution between a range of 1.0 and 3.5;coating the shape-forming material with the liquid binder solution;substantially dehydrating the shape-forming material;pouring a hot liquid metal into the casting mold; andallowing said hot liquid metal to cool to form a molded part.2. The method for inorganic binder casting according to claim 1 , wherein forming the shape-forming material by printing the shape-forming material using the plurality of additive material printers to form the casting mold further comprises:providing at least one XYZ-axis additive material printer;printing at least a first portion of the shape-forming material with the at least one XYZ-axis additive material printer; andprinting at least ...

Chill Plate for Equiax Casting Solidification Control For Solid Mold Casting of Reticulated Metal Foams

A method to manufacture reticulated metal foam via a dual investment solid mold includes pouring molten metal material into a mold while the mold is located on a chill plate. A method to manufacture reticulated metal foam includes pouring molten metal material into a mold while the mold is located on a chill plate, the chill plate configured to apply an externally driven temperature gradient in the mold so that solidification progresses from the chilled end to the non-chilled end 1. A method to manufacture reticulated metal foam , comprising:pouring molten metal material into a mold while the mold is located on a chill plate operable to provide chilling of an extent that a casting formed by the mold remains equiaxial with crystallization nucleating from all surfaces.2. The method as recited in claim 1 , further comprising:pre-investing a precursor with a diluted pre-investment ceramic plaster to encapsulate the precursor; andinvesting the encapsulated precursor with a ceramic plaster to form the mold.3. The method as recited in claim 2 , wherein the precursor is a reticulated foam structure.4. The method as recited in claim 2 , wherein the precursor is a polyurethane reticulated foam structure.5. The method as recited in claim 2 , wherein the precursor is completely encapsulated with the diluted pre-investment ceramic plaster.6. The method as recited in claim 2 , further comprising claim 2 , coating the precursor in a molten wax to increase ligament thickness.7. The method as recited in claim 2 , further comprising claim 2 , coating the precursor in a molten wax to increase ligament thickness to provide an about 90% air to 10% precursor ratio.8. The method as recited in claim 2 , wherein the ceramic plaster is more rigid than the diluted pre-investment ceramic plaster.9. The method as recited in claim 2 , wherein the diluted pre-investment ceramic plaster is about 55:100 water to powder ratio.10. The method as recited in claim 2 , wherein the ceramic plaster is ...

CASTING MOLD, METHOD OF MANUFACTURING SAME, TiAl ALLOY CAST PRODUCT, AND METHOD OF CASTING SAME

A casting mold to cast a TiAl alloy includes a casting mold body formed into a bottomed shape and provided with a cavity. The casting mold body includes a reaction-resistant layer provided on the cavity side, formed from a refractory material containing at least one of cerium oxide, yttrium oxide, and zirconium oxide and a back-up layer formed on the reaction-resistant layer. The back-up layer includes a weakening layer formed from a refractory material including a silica material in a range from 80% by mass to 100% by mass inclusive, the silica material containing cristobalite in a range from 26% by mass to 34% by mass inclusive and the rest being fused silica, the weakening layer being designed to reduce casting mold strength and a shape-retention layer formed from a refractory material. 1. A casting mold to cast a TiAl alloy , comprising:a casting mold body formed into a bottomed shape and provided with a cavity into which a molten TiAl alloy is to be poured, wherein a reaction-resistant layer provided on the cavity side, formed from a refractory material containing at least one of cerium oxide, yttrium oxide, and zirconium oxide, and configured to suppress a reaction with the molten TiAl alloy, and', 'a back-up layer formed on the reaction-resistant layer, and, 'the casting mold body includes'} a weakening layer formed from a refractory material including a silica material in a range from 80% by mass to 100% by mass inclusive, the silica material containing cristobalite in a range from 26% by mass to 34% by mass inclusive and the rest being fused silica, the weakening layer being designed to reduce casting mold strength, and', 'a shape-retention layer formed from a refractory material and designed to retain a casting mold shape., 'the back-up layer includes'}2. The casting mold according to claim 1 , wherein the refractory material forming the weakening layer includes the silica material in a range from 90% by mass to 100% by mass inclusive.3. The casting mold ...

REFRACTORY MOLD AND METHOD OF MAKING

A refractory mold is disclosed. The refractory mold includes a fugitive pattern assembly comprising a hollow sprue that comprises a sprue wall disposed about a longitudinal axis; a pattern disposed outwardly of the sprue wall; and an outwardly extending gate attached to and extending between the sprue wall and the pattern, the hollow sprue, pattern and gate each formed from a fugitive material; and a refractory mold formed on and having a mold cavity defined by an outer surface of the fugitive pattern assembly. 1. A refractory mold , comprising: a fugitive pattern assembly comprising a hollow sprue that comprises a sprue wall disposed about a longitudinal axis; a pattern disposed outwardly of the sprue wall; and an outwardly extending gate attached to and extending between the sprue wall and the pattern , the hollow sprue , pattern and gate each formed from a fugitive material; and a refractory mold formed on and having a mold cavity defined by an outer surface of the fugitive pattern assembly.2. The refractory mold of claim 1 , wherein the fugitive pattern assembly further comprises a runner disposed proximate an end claim 1 , and wherein the refractory mold is also formed on an outer surface of the runner and comprises a runner portion of the mold cavity.3. The refractory mold of claim 2 , wherein the runner is disposed within and attached to an inner surface of the sprue wall.4. The refractory mold of claim 2 , wherein the runner is disposed proximate a lower end of the sprue wall.5. The refractory mold of claim 2 , wherein the runner comprises a plurality of outwardly extending spokes claim 2 , each spoke attached to an inner surface of the sprue wall.6. The refractory mold of claim 2 , wherein the hollow sprue comprises a hollow cylindrical sprue.7. The refractory mold of claim 2 , wherein the pattern comprises a plurality of patterns disposed about the outer surface of the hollow sprue.8. The refractory mold of claim 2 , wherein the pattern assembly further ...

METHOD OF FORMING A CASTING MOLD PATTERN

A method of forming a casting mold pattern that includes a core comprises mounting the core in a fixture such that the core is free of flexing imposed by the fixture. Material is removed from and/or added to a first and/or second mounting surface of the core. The core is then positioned in a die, and wax is conducted into the die to form the pattern. The amount of material removed from the first and/or second mounting surface is such that the core will be within a predetermined range of acceptable positions when the core is in the die with the first mounting surface engaging a first core locating surface of the die end with the second mounting surface engaging a second core locating surface of the die. The range of acceptable positions is determined relative to an ideal position of an ideal core. 1. A method of forming a casting mold pattern that includes a core , the core having a length , a first end , and a second end , the second end being spaced apart from the first end by the length , the core also having a first mounting surface adjacent the first end of the core and a second mounting surface adjacent the second end of the core , said method comprising the steps of:(a) removing material from and/or adding material to the first mounting surface and/or the second mounting surface:(b) positioning the core in a pattern forming die alter removing material from and/or adding material to the first mounting surface and/or the second mounting surface, the pattern forming die having a first core locating surface to support the first end of the core and a second core locating surface to support the second end of the core, the core being positioned in the pattern forming die with the first mounting surface in engagement with the first core locating surface and with the second mounting surface in engagement with the second core locating surface; and 'the material being removed from and/or added to the first mounting surface and/or the second mounting surface being in an ...

MANUFACTURING METHOD TO CAST PARTS WITH ADDITIVE MANUFACTURING GEOMETRY COMPLEXITY

Molds are produced by additive manufacturing and define parts cavities with part infills that can be ribbed or cellular. The molds are processed to sequentially remove infills to open part cavities to which part materials are introduced. Embedded or captured parts can be molded, and thermal channels can be provided to thermally isolate different materials. 1. A method , comprising:selecting at least a mold material and a sacrificial material; and at least a portion of a mold with the mold material, wherein the mold includes at least one mold ports, and', 'defining at least a portion of a part cavity with the sacrificial material., 'with an additive process, defining, layer-by-layer2. The method of claim 1 , further comprising defining at least one fill port with the sacrificial material claim 1 , wherein the fill port is coupled to the part cavity.3. The method of claim 2 , wherein defining at least the portion of the mold with the mold material includes defining at least a portion of a part outline in the mold material or defining at the least the portion of the part cavity with the sacrificial material or both.4. The method of claim 3 , wherein the portion of the mold defined with the mold material includes a mold infill.5. The method of claim 4 , wherein the mold infill defined with the mold material includes one or more of a ribbed mold infill and a cellular mold infill.6. The method of claim 4 , wherein either the portion of the part cavity defined with the sacrificial material includes a part infill or portion of the sacrificial material defines a sacrificial material infill that is a cellular or ribbed infill.7. The method of claim 6 , wherein the fill ports contain the sacrificial material claim 6 , and further comprising removing the sacrificial material from the part cavity and the fill ports.8. The method of claim 6 , further comprising claim 6 , with the fill ports claim 6 , removing the sacrificial material from the part cavity.9. The method of claim 7 ...

System and Method for Complex Objects Molding

A molding system and method, allowing for the repeated use of the same molding insert for purposes of elaborate objects molding is described. The proposed method allows for multiple moldings of intricate shapes and curvatures improving the mass production of the jewelry moldings. During the process, the raw molding material is squeezed through the narrow opening inside the mold form under pressure. As the molding material enters the mold form, it is coated with a coating fluid. After the curing, the molding material could be easily removed through a narrow cavity opening, promptly reassembling back to the shape of the insert for continuous use in the next steps of the molding procedure. 1. An unmixable combination comprising:an elastomer having a property to change into a more rigid physical state under an outside influence;a fluid, having a property to remain unchanged under said outside influence;said elastomer further having a property to be protruded to enter a hollow cavity, while said fluid spreads on the said elastomer's surface, preventing said elastomer from binding with itself and other surfaces;said unmixable combination being used to fill said hollow cavity and further used in a molding process.2. The unmixable combination of claim 1 , wherein said elastomer is selected from the group consisting of high temperature vulcanizing silicone (HTV) claim 1 , mold making rubber claim 1 , natural rubber claim 1 , room temperature vulcanization (RTV) silicone putty claim 1 , thermoplastic rubbers (also known as thermoplastic elastomers claim 1 , or TPE) claim 1 , and reactoplastic polymers.3. The unmixable combination of claim 1 , wherein said fluid is selected from the group consisting of mineral oil claim 1 , organic oil claim 1 , siloxanes claim 1 , and Mold Release liquids.4. The unmixable combination of claim 1 , wherein fluid is further mixed with filler powder selected from the group consisting of metal powders claim 1 , metal oxide powders claim 1 , ...

FORMING COOLING PASSAGES IN COMBUSTION TURBINE SUPERALLOY CASTINGS

Cooling passages () are formed in components for combustion turbine engines, such as blades (), vanes (), ring segments () or castings in transitions (), during investment casting, through use of ceramic shell inserts () within the casting mold (). Ceramic posts () formed in the ceramic shell insert () have profiles conforming to corresponding profiles of partially completed cooling passages (). Posts () are removed after superalloy component casting, forming the partially completed cooling passages, which are subsequently completed by removing remaining superalloy material along the cooling passage path. 1. A method for forming a cooling passage in an investment cast , superalloy component for a combustion turbine engine , comprising:providing a wax injection mold defining a mold cavity, whose mold cavity surface conforms to a corresponding surface profile of a component for a combustion turbine engine;providing a ceramic shell insert, having an insert surface profile and at least one ceramic post projecting from the insert surface, which in combination conform to a corresponding surface profile of a partially completed cooling passage in the engine component;inserting the ceramic shell insert into the wax injection mold, the shell insert surface and each ceramic post forming part of the mold cavity surface, each post projecting into the mold cavity;filling the mold cavity with wax, enveloping each post therein;hardening the wax, creating a wax pattern that embeds the ceramic shell insert and each post therein;removing the wax injection mold, the hardened wax pattern, along with the insert surface and each ceramic post conforming to the component surface profile;enveloping the hardened wax pattern and embedded ceramic shell insert in ceramic slurry;firing the ceramic slurry, thereby hardening the slurry into an outer ceramic shell, which is joined to the ceramic shell insert, and eliminating the wax, the joined outer ceramic shell and ceramic shell insert defining ...

Ceramic and refractory metal core assembly

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.

LOST CORE STRUCTURAL FRAME

A lost core mold component comprises a first leg and a second leg with a plurality of crossover members connecting the first and second legs. The plurality of crossover members includes outermost crossover members spaced from each other. Adjacent ends of each of the first and second legs, and second crossover members are spaced closer to each other than are the outermost crossover members. Central crossover members extend between the first and second leg and between the second crossover members. The outermost crossover members extend for a first cross-sectional area. The second crossover members extend for a second cross-sectional area and the central crossover members extend for a third cross-sectional area. The first cross-sectional area is greater than the second cross-sectional area. The second cross-sectional area is greater than the third cross-sectional area. A gas turbine engine and component are also disclosed. 1. A lost core mold component comprising:a first leg and a second leg, with a plurality of crossover members connecting said first and second legs, with said plurality of crossover members including outermost crossover members spaced from each other and adjacent ends of each of said first and second legs, second crossover members spaced closer to each other than are said outermost crossover members, and central crossover members extending between said first and second leg and between said second crossover members; andsaid outermost crossover members extending for a first cross-sectional area, said second crossover members extending for a second cross-sectional area and said central crossover members extending for a third cross-sectional area, with said first cross-sectional area being greater than said second cross-sectional area and said second cross-sectional area being greater than said third cross-sectional area.2. The lost core mold component as set forth in claim 1 , wherein a ratio of said first cross-sectional area to said second cross- ...

Stackable core system for producing cast plate heat exchanger

A method of forming a cast heat exchanger plate includes forming at least one hot core plate defining internal features of a one piece heat exchanger plate and at least one first set of interlocking features. At least one cold core plate is formed defining external features of the heat exchanger plate and at least one second set of interlocking features. A core assembly is assembled wherein each hot core plate is directly interlocked to the at least one cold core plate. A wax pattern is formed with the core assembly. An external shell is formed over the wax pattern. The wax pattern is removed to form a space between the core assembly and the external shell. The space is filled with a molten material and cures the molten material. The external shell is removed. The core assembly is removed. A core assembly for a cast heat exchanger is also disclosed.

METHOD FOR MANUFACTURING CASTING USING LOST WAX PROCESS

A wax pattern forming die to form a wax pattern is first fabricated, and a molten wax is poured into a cavity in the wax pattern forming die to fabricate the wax pattern. Subsequently, the wax pattern is bonded to a casting sprue pattern made of the wax and fabricated separately from the wax pattern to fabricate an integrated pattern, a surface of the integrated pattern is coated with ceramics, sintering is effected, then the integrated pattern is molten and effused to fabricate a mold to cast a casting with a casting sprue. Further, a molten metal is poured into the mold and cured, then the mold is crushed to take out the casting with the casting sprue, and the casting sprue is cut off from the casting with a casting sprue to fabricate a casting. 1. A method for manufacturing a casting using a lost wax process , comprising steps of: fabricating a wax pattern forming die to form a wax pattern; pouring a molten wax into a cavity in the wax pattern forming die to fabricate the wax pattern; bonding the wax pattern to a casting sprue pattern made of the wax and fabricated separately from the wax pattern to fabricate an integrated pattern; coating a surface of the integrated pattern with ceramics , performing sintering , and then melting and effusing the integrated pattern to fabricate a mold to mold a casting with a casting sprue; pouring a molten metal into the mold , curing the metal , and then crushing the mold to take out the casting with a casting sprue; cutting off a casting sprue from the casting with a casting sprue to fabricate the casting ,wherein the wax pattern forming die is a resin forming die that is sterically formed by using stereolithography or a three-dimensional printer and has a heat resistance temperature higher than a temperature of the molten wax.2. The method for manufacturing a casting using a lost wax process according to claim 1 , wherein the plurality of wax patterns are fabricated at the time of fabrication of the wax pattern claim 1 , and ...

MOLD COMPOSITION S AND METHODS FOR CASTING TITANIUM AND TITANIUM ALUMINIDE ALLOYS

The disclosure relates generally to mold compositions and methods of molding and the articles so molded. More specifically, the disclosure relates to mold compositions, intrinsic facecoat compositions, and methods for casting titanium-containing articles, and the titanium-containing articles so molded. 1. A method for forming a mold for casting a titanium-containing article , said method comprising:combining calcium aluminate with a liquid to produce a slurry of calcium aluminate, wherein the percentage of solids in the initial calcium aluminate/liquid mixture is about 70% to about 80% and the viscosity of the slurry is about 50 to about 150 centipoise;adding oxide particles into the slurry such that the solids in the final calcium aluminate/liquid mixture with the large-scale oxide particles is about 75% to about 90%;introducing the slurry into a mold cavity that contains a fugitive pattern; andallowing the slurry to cure in the mold cavity to form a mold of a titanium-containing article.2. A casting method for titanium and titanium alloys comprising:obtaining an investment casting mold composition comprising calcium aluminate and aluminum oxide, wherein the calcium aluminate is combined with a liquid to produce a slurry of calcium aluminate, and wherein the solids in the final calcium aluminate/liquid mixture with the large scale alumina is about 75% to about 90%;pouring said investment casting mold composition into a vessel containing a fugitive pattern;curing said investment casting mold composition;removing said fugitive pattern from the mold;firing the mold;preheating the mold to a mold casting temperature;pouring molten titanium or titanium alloy into the heated mold;solidifying the molten titanium or titanium alloy and forming a solidified titanium or titanium alloy casting; andremoving the solidified titanium or titanium alloy casting from the mold. This application is a divisional of U.S. application Ser. No. 13/407,917, filed on Feb. 29, 2012 and entitled ...

METHOD OF FREEZE-DRYING

A method of freeze-drying comprising rapidly freezing either liquid or supercritical carbon dioxide in and around a material having pores at a rate of at least 0.2° C./min to limit the size of crystals formed from the carbon dioxide so as to avoid the formation of gas bubbles and damage to the pores and exposure of the material to gas-liquid interfaces. During freezing a solid layer primarily of solid carbon dioxide is formed on and surrounding the material by transferring heat with a cryogenic liquid circulating about the material. This solid layer protects the material from gas-liquid interfaces and surface tension before decreasing pressure about the material by venting carbon dioxide. 1. A method of preserving a material in contact with a first fluid comprising the steps of;replacing the first fluid with a first non-gaseous fluid,cooling the first non-gaseous fluid to cause the first non-gaseous fluid to freeze to form a solid, andcharacterized by:forming a solid layer of the solid on and surrounding the material,then decreasing pressure about the material by expanding the first non-gaseous fluid to form a gas.2. The method of wherein the decreasing pressure is at a rate of at least 0.001 Mpa/min and less than or equal to 2.0 Mpa/min.3. The method of wherein the forming a solid layer of the solid on and surrounding the material comprises transferring heat with a liquid circulating about the material.4. The method of wherein the first fluid is non-gaseous.5. The method of wherein the replacing the first fluid with the first non-gaseous fluid comprises flushing the first fluid from the material with the first non-gaseous fluid.6. The method of comprising subliming the solid from the material.7. The method of including;preserving a material containing at least one pore,subjecting the material to an impregnating agent with the impregnating agent being non-gaseous at the temperature and pressure conditions at which the first non-gaseous fluid is sublimed and with the ...

FIBER-REINFORCED CASTING WAX PRODUCT

A casting wax product including a casting wax and fibers distributed within the casting wax. The casting wax may be a standard casting wax. The currently preferred volume percent of the fibers is no more than 5%. The currently preferred aspect ratio of the fibers is between 10:1 and 25:1. The preferred fiber material is organic. Among other qualities, the casting wax product has improved slump resistance, improved rigidity, and improved strength. 1. A casting wax product comprising:a casting wax; anda plurality of fibers within the casting wax.2. A casting wax product as defined in wherein the fibers are organic fibers.3. A casting wax product as defined in wherein the fibers comprise no more than approximately 5% by volume of the product.4. A casting wax product as defined in wherein the fibers comprise 2% to 3% by volume of the product.5. A casting wax product as defined in wherein the organic fibers include at least one of polyester claim 2 , polyamide claim 2 , and rayon.6. A casting wax product as defined in wherein the length of the fibers is less than or equal to approximately 1 mm.7. A casting wax product as defined in wherein the diameters of the fibers are in the range of 6 microns to 20 microns.8. A casting wax product as defined in wherein the aspect ratio of the fibers is between 5:1 and 55:1 inclusive.9. A casting wax product as defined in wherein the aspect ratio of the fibers is between 15:1 and 20:1 inclusive.10. A method of manufacturing a casting wax product comprising:providing a casting wax; andreinforcing the casting wax with a plurality of fibers.11. A method as defined in wherein the fibers are organic fibers.12. A method as defined in wherein the fibers comprise no more than approximately 5% by volume of the casting wax product.13. A method as defined in wherein the fibers comprise 2% to 3% by volume of the casting wax product.14. A method as defined in wherein the organic fibers include at least one of polyester claim 11 , polyamide claim ...

A HYBRID COMPONENT WITH COOLING CHANNELS AND CORRESPONDING PROCESS

A process for forming a component is provided. The process includes providing a cooling channel flow definition at least partially about a core comprising a ceramic matrix composite material. A metal material is cast about the core and the cooling channel flow definition to form an outer metal shell. In addition, a cooling channel is formed from the cooling channel flow definition in the component. 1. A process forming a component comprising:providing a cooling channel flow definition at least partially about a core comprising a ceramic matrix composite material;casting a metal material about the core and the cooling channel flow definition to form an outer metal shell; andforming a cooling channel from the cooling channel flow definition in the component.2. The process of claim 1 , wherein the forming a cooling channel flow definition comprises depositing a channel defining material on the core in a pattern corresponding to a desired dimension of the cooling channel.3. The process of claim 2 , wherein the channel defining material comprises a ceramic material selected from the group consisting of alumina claim 2 , zircon claim 2 , silica claim 2 , and mixtures thereof.416. The process of claim 2 , wherein the forming a cooling channel () comprises removing an amount of the channel defining material to a degree effective to form the cooling channel.5. The process of claim 4 , wherein the removing is done by a leaching process.6. The process of claim 2 , further comprising applying the channel defining material about an entirety of a perimeter of the core.7. The process of claim 6 , further comprising:{'b': '25', 'forming a wax region about the core and the cooling channel flow definition ();'}forming an outermost shell about the wax region;removing the wax region to form a void region; andcasting a metal material within the void region to form the component.8. The process of claim 7 , wherein the outermost shell is formed from a ceramic material.9. The process of ...

TURBINE WHEEL PROCESS IMPROVEMENT THAT REDUCES THE INCOMING IMBALANCE AND LOWERING THE IMPACT ON PERFORMANCE AND DURABILITY WHILE KEEPING THE SCRAP LOW

A number of variations may include a method that may include producing a turbine wheel may include; designing a turbine wheel may include a backwall opposite a nose; forming a wax-pattern of the turbine wheel; casting the turbine wheel; determining the center of gravity of the turbine wheel; identifying an axis of rotation of the turbine wheel; and machining the backwall of the turbine wheel. 1. A method comprising: designing a turbine wheel comprising a backwall opposite a nose;', 'forming a wax-pattern of the turbine wheel;', 'casting the turbine wheel;', 'determining the center of gravity of the turbine wheel;', 'identifying an axis of rotation of the turbine wheel corresponding to the center of gravity; and', 'machining the backwall of the turbine wheel., 'producing a turbine wheel comprising;'}2. The method as set forth in wherein determining the center of gravity of the turbine wheel comprises performing a mass balance check on the turbine wheel.3. The method as set forth in wherein machining the backwall of the turbine wheel comprises machining the backwall normal to the axis of rotation of the turbine wheel.4. The method as set forth in wherein machining the backwall of the turbine wheel comprises machining the backwall normal to the axis of rotation of the turbine wheel and wherein the backwall further comprises a first portion centered within the backwall and an outer machined portion offset from the first portion by a draft angle ranging from about one degree to about ten degrees.5. The method as set forth in wherein machining the backwall of the turbine wheel comprises machining the backwall normal to the axis of rotation of the turbine wheel and wherein the backwall further comprises a first portion centered within the backwall and a machined portion offset from the first portion by a draft angle ranging from about two degrees to about five degrees.6. The method as set forth in ; further comprising:assembling the turbine and a shaft to form a turbine ...

Dual Investment Technique for Solid Mold Casting of Reticulated Metal Foams

A method to manufacture reticulated metal foam via a dual investment solid mold, includes pre-investment of a precursor with a diluted pre-investment ceramic plaster then investing the encapsulated precursor with a ceramic plaster. 1. A method to manufacture reticulated metal foam via a dual investment solid mold , comprising:pre-investing a precursor with a diluted pre-investment ceramic plaster to encapsulate the precursor to form an encapsulated precursor, the precursor is a reticulated foam; andinvesting the encapsulated precursor with a ceramic plaster.2. The method as recited in claim 1 , wherein the precursor is a reticulated foam diluted pre-investment ceramic plaster is diluted greater than a manufacturer recommended ratio.3. The method as recited in claim 1 , wherein the precursor is a polyurethane foam.4. The method as recited in claim 1 , wherein the precursor is completely encapsulated with the diluted pre-investment ceramic plaster.5. The method as recited in claim 1 , further comprising claim 1 , coating the precursor in a molten wax to increase ligament thickness.6. The method as recited in claim 1 , further comprising claim 1 , coating the precursor in a molten wax to increase ligament thickness to provide an about 90% air to 10% precursor ratio.7. The method as recited in claim 1 , wherein the ceramic plaster is more rigid than the diluted pre-investment ceramic plaster.8. The method as recited in claim 1 , wherein the diluted pre-investment ceramic plaster is about 55:100 water to powder ratio diluted to a ratio greater than 39-42:100 water to powder ratio.9. The method as recited in claim 1 , wherein the ceramic plaster is about 28:100 water to powder ratio.10. A method to manufacture reticulated metal foam via a dual investment solid mold claim 1 , comprising:coating a precursor in a molten wax to increase ligament thickness;pre-investing the waxed precursor with a diluted pre-investment ceramic plaster to encapsulate the precursor, wherein the ...

GOLF CLUB HEADS

A cast cup can include a forward portion of a golf club head, including a hosel, a face portion, and forward portions of a crown, sole, heel and toe. A rear ring can be formed separately from the cast cup and coupled to heel and toe portions of the cast cup to form a metallic club head body, such that the club head body defines a hollow interior region, a crown opening, and a sole opening. The cast cup and rear ring can be cast of titanium alloys. Composite crown and sole inserts can then be coupled to the crown opening and sole opening. The face portion of the cast cup can have a desirably complex geometry. The rear surface of the face portion of the cast cup can be modified before the rear ring is attached. 1. A fairway wood type golf club head comprising:a metallic cast cup comprising a forward portion of the club head, including a hosel, a striking face, a forward portion of a crown, and a forward portion of a sole;a metallic rear ring formed separately from the cast cup and coupled to heel and toe portions of the cast cup to form a club head body, the club head body defining a hollow interior region, a crown opening, and a sole opening;a metallic sole plate coupled to the sole opening; anda composite crown insert coupled to the crown opening.2. The club head of claim 1 , wherein the cast cup comprises a titanium alloy.3. The club head of claim 2 , wherein the cast cup is composed entirely of a titanium alloy.4. The club head of claim 2 , wherein the cast cup comprises a titanium alloy including 6.75% to 9.75% aluminum by weight and 0.75% to 3.25% molybdenum by weight.5. The club head of claim 1 , wherein the rear ring comprises a titanium alloy.6. The club head of claim 1 , wherein the rear ring comprises steel.7. The club head of claim 1 , wherein the rear ring comprises aluminum.8. The club head of claim 1 , wherein the cast cup further comprises a slot in the forward portion of the sole.9. The club head of claim 1 , wherein the rear ring is welded to the ...

INVESTMENT CASTING COMPOSITIONS, MOLDS, AND RELATED METHODS

Provided are slurry compositions and methods for producing investment casting molds. These compositions include a refractory material, a binder, a solvent, and a thixotropic agent comprising a polymer emulsion. Implementation of these slurry compositions enables a reduction in the number of backup layers in an investment casting shell, while retaining similar viscosity characteristics and similar or greater strength characteristics in the finished investment mold. 1. A slurry composition for investment casting comprising:a refractory material;a binder;a solvent; anda thixotropic agent comprising a polymer emulsion.2. The composition of claim 1 , wherein the polymer emulsion is an aqueous emulsion.3. The composition of claim 1 , wherein the polymer emulsion comprises an alkali-swellable polymer.4. The composition of claim 3 , wherein the alkali-swellable polymer comprises a hydrophobically modified ester of methacrylic acid.5. The composition of claim 1 , further comprising an aluminum phyllosilicate clay.6. The composition of claim 5 , wherein the aluminum phyllosilicate clay is present in an amount ranging from a weight ratio of 1:6 to 4:1 relative to the polymer emulsion.7. The composition of claim 1 , wherein the polymer emulsion is present in an amount ranging from 0.07 weight percent to 0.75 weight percent claim 1 , based on the overall weight of the composition.8. The composition of claim 1 , wherein the composition has an overall solids content ranging from 50 weight percent to 75 weight percent claim 1 , based on the overall weight of the composition.9. The composition of claim 1 , wherein the binder comprises colloidal silica.10. The composition of claim 1 , wherein the composition displays a working viscosity of 20 Poise when subjected to a yield stress ranging from 25 dynes/cmto 800 dynes/cm.11. The composition of claim 1 , wherein the binder comprises a styrene-butadiene latex.12. The composition of claim 1 , wherein the binder comprises a polyvinyl ...

Mould for monocrystalline casting

The invention relates to the field of monocrystalline casting, and more specifically to a mold ( 1 ) for monocrystalline casting, and also to fabricating and using the mold. In particular, the mold ( 1 ) presents a mold cavity ( 7 ) comprising a first volume ( 7 a ), a second volume ( 7 b ) and a grain duct ( 4 ). The second volume ( 7 b ) is situated on the first volume ( 7 a ), being in communication therewith, and includes at least one horizontal projection relative to the first volume ( 7 a ). The grain duct ( 4 ) has a bottom end ( 4 a ) connected to the first volume ( 7 a ) and a top end ( 7 b ) adjacent to said horizontal projection of the second volume ( 7 b ). The mold ( 1 ) also has a separator member ( 11 ) interposed between the second volume ( 7 b ) of the mold cavity ( 7 ) and the top end ( 4 b ) of the grain duct ( 4 ).

GOLF CLUB HEADS WITH TITANIUM ALLOY FACE

Disclosed golf club head bodies are cast of 9-1-1 titanium with the face plate being cast as a unitary part of the body along the with crown, sole, skirt and hosel. Due to the 9-1-1 titanium material, the face plate and other portions of the body can have a reduced alpha case thickness and resulting greater durability. This can eliminate the need to reduce the alpha case thickness using hydrofluoric acid or other dangerous chemical etchants. Casting methods can include preheating the casting mold to a lower than normal temperature, to further reduce the amount of oxygen transferred from the mold to the 9-1-1 titanium during casting. 1. A wood-type golf club head body comprising:a crown, a sole, skirt, a face plate, and a hosel;the body defining a hollow interior region and at least one opening in the crown or sole providing access to the hollow interior region;the body being cast substantially entirely of 9-1-1 titanium; andthe body being cast as a single unitary casting, with the face plate being formed integrally with the crown, sole, skirt, and hosel.2. The body of claim 1 , wherein the body comprises substantially no fluorine atoms.3. The body of claim 1 , wherein the face plate is not chemically etched.4. The body of claim 1 , wherein the face plate has an alpha case thickness of 0.30 mm or less.5. The body of claim 1 , wherein the face plate has an alpha case thickness of 0.15 mm or less.6. The body of claim 1 , wherein the face plate has an alpha case thickness of 0.07 mm or less.7. The body of claim 1 , wherein the body is configured to form a golf club head having a volume of between approximately 300 cmand approximately 490 cm.8. The body of claim 1 , wherein the body is configured to form a golf club head having a volume of between approximately 120 cmand approximately 250 cm.9. The body of claim 1 , wherein the body is configured to form a golf club head having a volume of between approximately 80 cmand approximately 140 cm.10. The body of claim 1 , ...

Golf club heads

A cast cup can include a forward portion of a golf club head, including a hosel, a face portion, and forward portions of a crown, sole, heel and toe. A rear ring can be formed separately from the cast cup and coupled to heel and toe portions of the cast cup to form a metallic club head body, such that the club head body defines a hollow interior region, a crown opening, and a sole opening. The cast cup and rear ring can be cast of titanium alloys. Composite crown and sole inserts can then be coupled to the crown opening and sole opening. The face portion of the cast cup can have a desirably complex geometry. The rear surface of the face portion of the cast cup can be modified before the rear ring is attached.

METHOD FOR PRODUCING A COMPONENT, COMPONENT AND TURBOMACHINE HAVING A COMPONENT

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. 1. A method for manufacturing a metallic component especially configured and designed for a turbomachine , wherea) for a precision-casting process, a wax model with a wax structure is produced, subsequentlyb) 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, subsequentlyc) 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,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.2. The method in accordance with claim 1 , characterized in that after the application of the ceramic coating controlled segmentation cracking originating from the component structural element occurs in the ceramic coating.3. The method in accordance with claim 1 , wherein application of the plastic-containing coating or of the fibre composite layer a material permeable for a hardenable plastic is first applied to the metallic component and subsequently the hardenable plastic is poured through the permeable material.4. The ...

REGENERATING AN ADDITIVELY MANUFACTURED COMPONENT TO CURE DEFECTS AND ALTER MICROSTRUCTURE

One embodiment includes a method to regenerate a component. The method includes additively manufacturing the component with at least a portion of the component in a near finished shape. The component is encased in a shell mold, the shell mold is cured, the encased component is placed in a furnace and the component is melted, the component is solidified in the shell mold, and the shell mold is removed from the solidified component. 1. A method to manufacture a component , the method comprising:additively manufacturing the component, at least a portion of which is in a near finished shape;encasing the component in a shell mold;curing the shell mold;placing the encased component in a furnace and melting the component;solidifying the component in the shell mold; andremoving the shell mold from the solidified component.2. The method of claim 1 , wherein the component is additively manufactured to have voids greater than 0 percent but less than approximately 15 percent by volume.3. The method of claim 1 , wherein the component is additively manufactured to have up to 15 percent additional material by volume in the near finished shape compared to a desired finished configuration.4. The method of claim 3 , wherein the component is a blade or vane and the up to 15 percent additional material by volume is located at a root or a tip of an airfoil of the component.5. The method of claim 1 , wherein encasing the component in a shell mold comprises encasing an entirety of the component in the shell mold such that an entire external surface of the component is covered by the shell mold.6. The method of claim 5 , wherein encasing the component in the shell mold comprises a process of:(a) dipping the entirety of the component in a ceramic slurry to form a layer of the shell mold on the entirety of the component, such that the layer is a ceramic layer; and(b) drying the layer of the shell mold; and(c) repeating steps (a) and (b) until an acceptable shell mold thickness is formed to ...

METHOD OF MANUFACTURING PRECISION CAST PARTS FOR VEHICLE EXHAUST SYSTEMS

A method of manufacturing precision cast parts for vehicle exhaust systems includes fabricating a model of a product to be manufactured using a substance selected from the group consisting of a wax and a plastic, forming a first coating layer on a surface of the model using a first slurry, forming a second coating layer on the surface of the model coated with the first coating layer using a second slurry, drying the first and second coating layers to form a mold and heating the mold to remove the model, pre-heating the mold, placing the mold in a ceramic box with a top portion open, and filling an inner part of the ceramic box with ceramic balls, and producing a product by injecting a molten metal into the mold to cast the product. 1. A method of manufacturing precision cast parts for vehicle exhaust systems , comprising:fabricating a model of a product to be manufactured using a substance selected from the group consisting of a wax and a plastic;forming a first coating layer on a surface of the model using a first slurry;forming a second coating layer on the surface of the model coated with the first coating layer using a second slurry;drying the first and second coating layers to form a mold and heating the mold to remove the model;pre-heating the mold, placing the mold in a ceramic box with a top portion open, and filling an inner part of the ceramic box with ceramic balls; andproducing a product by injecting a molten metal into the mold to cast the product.2. The method of claim 1 , further comprising heating the ceramic balls to a temperature of 500 to 700° C. to remove foreign substances from surfaces of the ceramic balls prior to the cast preparation.3. The method of claim 1 , wherein the cast preparation comprises pre-heating the mold to 500 to 1 claim 1 ,200° C.4. The method of claim 1 , wherein the step of producing a product comprises casting the product in a vacuum state to prevent oxidation of the molten metal.5. The method of claim 1 , wherein the ...

ADDITIVELY MANUFACTURED INTERLOCKING CASTING CORE STRUCTURE WITH CERAMIC SHELL

The present disclosure relates to a method of forming a cast component and a method of forming a casting mold. The method is performed by connecting at least one wax gate component to a ceramic core-shell mold. The ceramic core-shell mold includes at least a first core portion, a first shell portion, and a second shell portion, wherein the first shell portion is adapted to interface with at least the second shell portion to form at least one first cavity between the core portion and the first and second shell portions. The core-shell mold may be inspected and assembled prior to connection of the wax gate component. At least a portion of the ceramic core-shell mold and the wax gate component is coated with a second ceramic material. The wax gate component is then removed to form a second cavity in fluid communication with the first cavity. 1. A method of fabricating a ceramic casting mold comprising the steps of:(a) connecting at least one wax component to a ceramic core-shell mold, the ceramic core-shell mold comprising at least:a first core portion;a first shell portion; anda second shell portion, wherein the first shell portion is adapted to interface with at least the second shell portion to form at least a portion of a first cavity between the core portion and the first and second shell portions;(b) applying a second ceramic material to coat at least a portion of the ceramic core-shell mold and the wax component with the second ceramic material; and(c) removing the wax component to form at least a second cavity in fluid communication with the first cavity.2. The method for fabricating a ceramic casting mold of claim 1 , wherein the core-shell mold is formed by:(i) contacting a cured portion of a workpiece with a liquid ceramic photopolymer;(ii) irradiating a portion of the liquid ceramic photopolymer adjacent to the cured portion through a window contacting the liquid ceramic photopolymer;(iii) removing the workpiece from the uncured liquid ceramic photopolymer; ...

Porous Tools and Methods of Making the Same

A porous tool includes a mold body and an additively-manufactured film attached to a surface of the mold body. The film includes a porous layer and a nonporous support layer. The porous layer may include a surface having an array of surface pore openings, a network of interconnected passages in fluid communication with the surface pore openings, and one or more lateral edges that have an array of edge pore openings in fluid communication with the interconnected passages. Methods of forming a porous tool include depositing additive material on a build surface using a directed energy deposition system to form a film while simultaneously subtracting selected portions of the additive material from the film using laser ablation. Methods of forming a molded component include conforming a moldable material to a shape using a porous tool that includes a mold body and an additively-manufactured film, and evacuating outgas from the moldable material through a porous layer of the film. 1. A method of forming a porous tool , the method comprising:depositing additive material on a build surface using a directed energy deposition system to form a film while simultaneously subtracting selected portions of the additive material from the film using laser ablation to form a porous layer in the film, the porous layer comprising a network of interconnected passages.2. The method of claim 1 , comprising:depositing a first layer of additive material on the build surface using the directed energy deposition system to form a support layer for the film;depositing a second layer of additive material on the first layer using the directed energy deposition system while simultaneously subtracting selected portions of the second layer using laser ablation to form interconnected passages that traverse through the second layer in the x-direction and/or the y-direction; anddepositing a third layer of additive material on the second layer using the directed energy deposition system while ...

BACKSIDE FEATURES WITH INTERMITTED PIN FINS

According to one embodiment, a heat shield panel for a combustor of a gas turbine engine is provided. The heat shield comprising: a panel body having a first surface configured to be oriented toward a combustion zone of a combustor, and a second surface opposite the first surface, the second surface being configured to be oriented toward a combustor liner of the combustor; a plurality of first pin fins projecting from the second surface of the panel body, wherein each of the plurality of first pin fins has a rounded top opposite the second surface; and one or more second pin fins projecting from the second surface of the panel body, wherein each of the one or more second pin fins has a flat top opposite the second surface. 1. A heat shield panel for a combustor of a gas turbine engine , comprising:a panel body having a first surface configured to be oriented toward a combustion zone of a combustor, and a second surface opposite the first surface, the second surface being configured to be oriented toward a combustor liner of the combustor;a plurality of first pin fins projecting from the second surface of the panel body, wherein each of the plurality of first pin fins has a rounded top opposite the second surface; andone or more second pin fins projecting from the second surface of the panel body, wherein each of the one or more second pin fins has a flat top opposite the second surface.2. The heat shield panel of claim 1 , wherein the one or more second pin fins are intermittently spaced amongst the plurality of first pin fins.3. The heat shield panel of claim 1 , wherein the one or more second pin fins are separated from each other by about 0.5 inches (1.27 centimeters).4. The heat shield panel of claim 1 , wherein the flat top of each of the one or more second pin fins is about parallel to the second surface where each of the one or more second pin fins are located.5. The heat shield panel of claim 1 , wherein each of the plurality of first pin fins are about ...

GOLF CLUB HEADS

A cast cup can include a forward portion of a golf club head, including a hosel, a face portion, and forward portions of a crown, sole, heel and toe. A rear ring can be formed separately from the cast cup and coupled to heel and toe portions of the cast cup to form a metallic club head body, such that the club head body defines a hollow interior region, a crown opening, and a sole opening. The cast cup and rear ring can be cast of titanium alloys. Composite crown and sole inserts can then be coupled to the crown opening and sole opening. The face portion of the cast cup can have a desirably complex geometry. The rear surface of the face portion of the cast cup can be modified before the rear ring is attached. 1. A method comprising:casting a cup of metallic material, the cast cup comprising a forward portion of a golf club head including an entire face portion, a forward portion of a crown, a forward portion of a sole, a heel portion, a toe portion, and a hosel;coupling a metallic rear ring to the heel portion and toe portion of the cast cup to form a metallic club head body, the rear ring forming a rear skirt of the club head body, the club head body defining a hollow interior region, a crown opening, and a sole opening;coupling a composite crown insert over the crown opening; andcoupling a composite sole insert over the sole opening.2. The method of claim 1 , wherein the cup and rear ring are cast of a titanium alloy.3. The method of claim 1 , wherein the cup is made of a first metallic material and the rear ring is made of a second metallic material having a lower density than the first metallic material.4. The method of claim 1 , further comprising casting the rear ring of metallic material prior to coupling the rear ring to the cast cup.5. The method of claim 1 , wherein coupling the rear ring to the cast cup comprises welding forward ends of the rear ring to the toe portion and heel portion of the cast cup.6. The method of claim 1 , wherein coupling the rear ...

CERAMIC CORE, MANUFACTURING METHOD FOR THE SAME, MANUFACTURING METHOD FOR CASTING USING THE CERAMIC CORE, AND CASTING MANUFACTURED BY THE METHOD

A ceramic core includes sintered ceramic powder and a hole opening on a surface of the ceramic core and having an opening portion with a maximum size of 100 μm or less. 1. A ceramic core including a sintered body of ceramic powder , whereinan opening portion of a hole present on a surface of the ceramic core has a maximum size of 100 μm or less.2. The ceramic core according to claim 1 , whereinthe ceramic core has a relative density of 60% or more.3. The ceramic core according to claim 1 , whereina fracture surface of the ceramic core includes transgranular fracture particle of ceramic powder.4. The ceramic core according to claim 3 , whereinthe ceramic core has a relative density of 60% or more.5. A manufacturing method for a ceramic core claim 3 , comprising:preparing an injection molding composition by mixing ceramic powder and a binder;manufacturing a ceramic compact by performing the injection molding of the injection molding composition; andmanufacturing a ceramic core by sintering the ceramic compact, wherein cumulative percentage of coarse powder with a particle diameter of more than 50 μm included in the ceramic powder is 30% or less on an integrated volume particle size distribution curve of the ceramic powder.6. The manufacturing method for a ceramic core according to claim 5 , whereinthe cumulative percentage of the micropowder with a particle diameter of 5 μm or less in the ceramic powder is 10 to 40%.7. A manufacturing method for a casting using a ceramic core claim 5 , comprising:{'claim-ref': {'@idref': 'CLM-00001', 'claim 1'}, 'manufacturing a lost-foam pattern by coating the ceramic core according to with a lost-foam material;'}manufacturing a mold by coating the lost-foam pattern with a refractory;filling the mold with a molten metal material;manufacturing a casting original model by solidifying the metal material; andproviding a hollow casting by removing the mold and the ceramic core from the casting original model.8. A manufacturing method for ...

CYLINDER HEAD FOR AN INTERNAL COMBUSTION ENGINE

A cylinder head includes an inner structural member having a plate forming a deck face of the cylinder head and forming at least one dished cylinder roof, and a plurality of cylinder head bolt columns extending from the plate. An outer member is supported by the inner structural member and forms a cooling jacket, intake ports, and exhaust ports. Passages of the cooling jacket are lined with metal walls in contact with the composite structure of the outer member. A method of forming a cylinder head includes positioning a structural insert and a lost core insert in a tool, and injecting material into the tool to form a body surrounding the structural insert and the lost core insert thereby forming a head preform. The lost core insert is shaped to form a cooling jacket and has a lost core material generally encapsulated in a metal shell. 1. A cylinder head for an internal combustion engine comprising:an inner structural metal member having a first plate forming a deck face of the cylinder head and forming a series of dished cylinder roofs, the inner member having cylinder head bolt columns extending from the first plate, exhaust valve guides connected to the first plate by first support arms, intake valve guides connected to the first plate by second support arms, and a second plate configured for mounting an exhaust manifold and extending at an angle to the first plate; andan outer composite member supported by the inner member and forming a body of the cylinder head including an intake side wall, first and second end wall, and a top wall opposed to the deck face, the outer member defining a cooling jacket, intake ports, and exhaust ports;wherein fluid passages of the cooling jacket are formed by metal walls in contact with and surrounded by the composite material of the outer member.2. The cylinder head of wherein the exhaust ports are formed by metal walls in contact with and surrounded by the composite material of the outer member.3. A cylinder head comprising:an ...

Method of Casting a Component Having Interior Passageways

A method of casting a component () having convoluted interior passageways (). A desired three dimensional structure corresponding to a later-formed metal alloy component is formed by stacking a plurality of sheets () of a fugitive material. The sheets contain void areas () corresponding to a desired interior passageway in the metal alloy component. A ceramic slurry material is cast into the three dimensional structure to form either a ceramic core () or a complete ceramic casting vessel (). If just a ceramic core is formed, a wax pattern is formed around the ceramic core and an exterior ceramic shell () is formed around the wax pattern by a dipping process prior to the removal of the fugitive material and wax. An alloy component having the desired interior passageway is cast into the casting vessel after the fugitive material is removed. 1. A method of casting a component , the method comprising:forming a plurality of sheets of fugitive material, each sheet corresponding to a respective layer of a desired three dimensional structure, at least some of the sheets each containing a respective void area in a location corresponding to a location of a first passageway within the desired three dimensional structure;stacking the sheets to form the three dimensional structure, void areas in predetermined adjacent sheets being aligned to define the first passageway within the three dimensional structure, wherein the three dimensional structure comprises an outer perimeter defining a fugitive mold die;injecting ceramic material slurry into the three dimensional structure and allowing the ceramic material to harden, the first passageway thus being filled with the ceramic material in a shape corresponding to the first passageway, wherein the fugitive mold die is filled with the ceramic material while forming an outer ceramic shell at the outer perimeter of the three dimensional structure, the forming of the outer ceramic shell in the fugitive mold die effective to eliminate a ...

Gas turbine component with cooling aperture having shaped inlet and method of forming the same

A method of manufacturing a cooled gas turbine component includes forming a core with an outer surface. The outer surface includes a core feature. The method also includes casting an outer wall of an airfoil about the core. The outer wall has an exterior surface and an interior surface. The interior surface includes a shaped inlet portion that corresponds to the core feature. Moreover, the method includes forming an outlet portion through the outer wall to fluidly connect the outlet portion to the shaped inlet portion. The shaped inlet portion and the outlet portion cooperatively define a cooling aperture through the outer wall.

Torque bar and methods for making

A torque bar manufactured by an additive manufacturing process is provided. The torque bar may include a torque bar body made of more than one metallic material. The torque bar may also include a geometry that comprises one or more voids and one or more webs, as well as a varied geometry in the direction of a longitudinal axis. The torque bars can exhibit characteristics, such as vibration damping, tuned stiffness, and tuned bending resistance in order to enhance dynamic stability.

POWDER INVESTMENT CASTING BINDER AND MOLDS DERIVED THEREFROM

A powder binder product for use in making a slurry for investment casting molds comprising Nano-sized powders; and an organic polymer powder, wherein it does not require aqueous colloidal silica to produce slurries used to build investment casting molds. The Nano-sized powders comprise fumed alumina, boehmite, fumed silica, or fumed titanium oxide or combinations thereof. The coarse refractory powder, combined with the powder binder for mold manufacture, comprises milled zircon, tabular alumina or fused alumina, fused silica, alumino-silicate, zirconia, and yttria or combinations thereof. The organic polymer in a powder binder comprises a cellulose-based material. A powder investment casting binder, that once fired, consists of up to 96 weight percent aluminum oxide. 1: A powder binder product for use in making a slurry for investment casting molds comprising:Nano-sized powders; andan organic polymer powder;wherein the composition of the Nano-sized powder comprises:boehmite or pseudo boehmite, 71% to 94%;aluminum oxide;silicon oxide, 2.5% to 23%; ortitanium oxide, 0.4% to 1.0%; andcombinations thereof.2: The powder binder product of claim 1 , wherein the composition of the Nano-sized powder comprises:pseudo boehmite;aluminum oxide;titanium oxide; andcombinations thereof.3: The powder binder product of claim 1 , wherein said Nano-sized powder is between 80 nm and 1.2 μm.4: The powder binder product of claim 1 , wherein the organic polymer is between 2.0 and 6.0% by weight of the total powder binder mass.5: The powder binder product of claim 1 , wherein the organic polymer comprises:at least one of a cellulose-based material or acrylic combined with polyethylene glycol.6: The powder binder product of claim 1 , wherein the organic polymer comprises:a cellulose-based material or acrylic combined with polyethylene glycol; anda methyl cellulose binder.7: The powder binder product of claim 1 , which claim 1 , when fired claim 1 , comprises:up to 96 weight percent ...

PROCESS OF LOST WAX MICRO CASTING WITH RECYCLING OF EXHAUSTED WAX

Recycling of exhausted wax in a process of lost wax micro casting. 2. Process of lost wax micro casting with recycling of exhausted wax according to claim 1 , wherein said step of removing ceramic residues claim 1 , ashes or other impurity by filtration is such as to reduce the ash content down to a level not higher than 0.05% by weight of the total of said second formulation of wax.3. Process of lost wax micro casting with recycling of exhausted wax according to claim 1 , wherein claim 1 , after or simultaneouly with said step of adding virgin wax claim 1 , a dye is also added.4. Process of lost wax micro casting with recycling of exhausted wax according to claim 3 , wherein said dye is added in an amount lower than 0.01% by weight of the total of said second formulation of wax.5. (canceled) The present invention relates to a process of lost wax microcasting with recycling of exhausted wax.It is known that the process of lost wax microcasting is commonly employed, for example, for the production of aeronautical or industrial components made of metallic material, which may be generally of the equiaxial type, or of the directional solidification (DS) tyoe, or of the “single crystal” (SX) solidification type.According to the process of lost wax microcasting, the realisation of the components takes place by preliminarily preparing a mold in which molten wax is injected, which, by solidifying by cooling, allows to obtain a model which is identical to the final component to be produced.The wax model is obtained by injection, using piston actuated presses. These machines inject molten wax within a mold according to well-defined parameters that depend on the geometry of the piece, and therefore on the complexity of the mold to be filled.Typically, many models are combined together to form a so-called cluster.The clusters are then covered with a shell constituted by a plurality of layers of refractory material, to give the shell the necessary strength.Each refractory layer ...

INVESTMENT-DIECASTING MOLD

An investment-diecasting mold has a thin inner investment casting ceramic layer surrounded by a thicker outer metallic diecasting material. The two layers, inner ceramic and outer metallic, provide a hybrid mold for the fabrication of near-to-net or near net shape amorphous alloy composed parts. The inner ceramic layer being appropriate for thermoconductivity and the casting of intricately designed parts, and the outer metallic diecasting mold for support of the inner investment casting layer and as a heat sink for quench of the molten amorphous alloys during use. 1. An investment-diecasting mold comprising:an inner investment casting mold for defining a cavity, the cavity shaped as a negative imprint for at least a portion of a part; andan outer diecasting mold, the outer diecasting mold encasing and operatively contacting the inner investment casting mold.2. The investment-diecasting mold of claim 1 , wherein the inner investment casting mold is composed of a thermally conductive ceramic material.3. The investment-diecasting mold of wherein the thermally conductive ceramic material is selected from the group consisting of alumina claim 2 , silicon claim 2 , nitride claim 2 , and silicon nitride.4. The investment-diecasting mold of claim 2 , wherein the inner investment casting mold has a thickness of from about 1 mm and about 4 mm.5. The investment-diecasting mold of claim 1 , wherein the outer diecasting mold is composed of a material selected from the group consisting of steel claim 1 , stainless steel claim 1 , aluminum claim 1 , copper claim 1 , and brass.6. The investment-diecasting mold of claim 5 , wherein the outer diecasting mold has an appropriate mass to act as a heat sink for quenching parts made of amorphous metals.7. The investment-diecasting mold of claim 6 , wherein the outer diecasting mold defines one or more cooling conduits for inclusion of water claim 6 , brine claim 6 , NaOH or oil.8. A method comprising:filling a gap formed between a wax ...

TURBINE AIRFOIL COOLING SYSTEM WITH LEADING EDGE IMPINGEMENT COOLING SYSTEM TURBINE BLADE INVESTMENT CASTING USING FILM HOLE PROTRUSIONS FOR INTEGRAL WALL THICKNESS CONTROL

A method of forming an airfoil (), including: abutting end faces () of cantilevered film hole protrusions () extending from a ceramic core () against an inner surface () of a wax die () to hold the ceramic core in a fixed positional relationship with the wax die; casting an airfoil including a superalloy around the ceramic core; and machining film cooling holes () in the airfoil after the casting step to form an pattern of film cooling holes comprising the film cooling holes formed by the machining step and the cast film cooling holes () formed by the film hole protrusions during the casting step. 1. A method of forming an airfoil , comprising:abutting end faces of cantilevered film hole protrusions extending from a ceramic core against an inner surface of a wax die to hold the ceramic core in a fixed positional relationship with the wax die;forming a wax pattern between the ceramic core and the wax die;removing the wax die;forming a ceramic shell that surrounds the wax pattern and contacts the end faces; andremoving the wax pattern;casting an airfoil comprising a superalloy around the ceramic core; andmachining film cooling holes in the airfoil after the casting step to form a pattern of film cooling holes comprising the film cooling holes formed by the machining step and cast film cooling holes formed by the film hole protrusions during the casting step.2. The method of claim 1 , wherein the film hole protrusions and the ceramic core form a monolithic body formed by a single casting operation.3. The method of claim 2 , further comprising bonding the ceramic shell to the end faces.4. The method of claim 1 , wherein each of the film hole protrusions comprise a shape configured to form a diffuser in a film cooling hole formed by the respective film hole protrusion.5. The method of claim 1 , further comprising forming the film hole protrusions on the ceramic core by assembling discrete film hole protrusion bodies into the ceramic core.6. A method of forming an airfoil ...

CAST-IN FILM COOLING HOLE STRUCTURES

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 comprises a ceramic material. A shape of the extension comprises 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 comprises an ellipse. The extension is connected to the investment core body by the connection portion. 1. A core element of an investment core for use in a casting process used to produce an airfoil , the core element comprising:a investment core body comprising a ceramic material;an extension comprising a ceramic material, wherein the extension is connected to and protruding from the investment core body, wherein a shape of the extension comprises a tube with a centerline axis passing through a center of the extension, wherein a shape of a cross-section of the extension taken along a plane perpendicular to the extension centerline axis comprises an ellipse; anda connection portion comprising a ceramic material, wherein the connection portion is connected to the investment core body and to the extension, wherein the extension is connected to the investment core body by the connection portion.2. The core element of claim 1 , wherein the shape of the cross-section of the extension comprises a circle.3. The core element of claim 1 , further comprising a channel disposed through the extension claim 1 , wherein the channel comprises a centerline axis passing through a center of the channel claim 1 , wherein a shape of a cross-section of the channel taken along a plane perpendicular to the channel centerline axis comprises an ellipse.4. The core element of claim 3 , wherein the shape of the cross-section of the channel ...

Coated Casting Core and Manufacture Methods

A casting core assembly includes a metallic core, a ceramic core having a compartment in which the portion of the metallic core is received, and a ceramic coating at least partially covering the metallic core and the ceramic core. 1. A casting core assembly comprising:a metallic core;a ceramic core having a compartment in which a portion of the metallic core is received; anda ceramic coating at least partially covering the metallic core and the ceramic core and having a median thickness of 0.5 mil to 1.5 mil.2. The assembly of wherein:a ceramic adhesive joint between the portion and the ceramic core.3. The assembly of wherein:the ceramic core is an airfoil feedcore; andthe metallic core is an outlet core.4. The assembly of wherein:the metallic core is a refractory metal core.5. The assembly of wherein:the ceramic core is silica-based.6. The assembly of wherein:the coating comprises at least 50% mullite and/or alumina by weight.7. The assembly of wherein:the coating is a single sole layer atop both the ceramic core and the metallic core.8. A pattern comprising:{'claim-ref': {'@idref': 'CLM-00001', 'claim 1'}, 'the assembly of ; and'}a wax material in which the assembly is partially embedded.9. A mold comprising:{'claim-ref': {'@idref': 'CLM-00001', 'claim 1'}, 'the assembly of ; and'}a shell, the metallic core having a distal portion embedded in the shell and the metallic core spanning a gap between the ceramic core and the shell.10. A process for forming a casting core assembly of claim 1 , the process comprising:molding a ceramic core over a portion of a metallic core; andapplying a ceramic coating at least partially covering the metallic core and the ceramic core.11. The process of further comprising:applying an additional ceramic coating to the metallic core before the molding.12. The process of wherein:the applying of the ceramic coating is to the ceramic core in an unfired state.13. The process of wherein:the applying is by chemical vapor deposition.14. The ...

PROCESS FOR PRODUCING A COUPLER KNUCKLE AND IMPROVED COUPLER KNUCKLE

A process for producing a coupler knuckle and an improved coupler knuckle design are provided. The process produces a coupler knuckle by constructing a mold having the shape of the coupler knuckle. The mold is coated with a material that is resistant to melting at the molten melt temperatures of the molten metal used to form the knuckle. With the mold coated, the cavities in the mold interior are filled by placing an inert material therein. The molten metal used for forming the knuckle contacts the mold and consumes it, while the coating serves to provide a shape for the knuckle. 1. A mold for producing a coupler knuckle provided for use as an in-service coupler knuckle , the mold comprising:a mold having a desired shape of the coupler knuckle to be produced, said mold having at least one cavity therein and at least one opening therein;the mold having a plurality of mold component sections, wherein said mold component sections are arrangeable together to form a representation of the desired shape of the coupler knuckle to be produced;wherein said at least one cavity communicates with an exterior of the mold through the at least one opening;wherein said mold component sections are formed from a consumable material;wherein said plurality of mold component sections when arranged together form the shape of the coupler knuckle to be produced, the mold component sections when arranged forming said at least one cavity and forming the at least one opening in said mold that communicates with said at least one cavity;wherein the arranged mold component sections define an interior mold surface formed therefrom, and wherein the arranged mold component sections define an exterior mold surface of the mold exterior formed therefrom, wherein said at least one cavity is formed by the interior mold surface;wherein said plurality of mold component sections when arranged together form a vertical passageway through said mold comprising a continuous pin bore that passes through each of ...

INVESTMENT MOLD SLURRY CURTAIN APPARATUS

An investment mold slurry curtain apparatus includes a slurry curtain of a slurry fluid, the slurry curtain having a length and a thickness, the length substantially greater than the thickness. The apparatus also includes an outlet configured to dispense the slurry fluid and form the slurry curtain. The investment mold slurry curtain apparatus may include and be described as an investment mold slurry coating apparatus including a conduit configured to receive a flow of a slurry fluid and an outlet operatively coupled to the conduit, the outlet configured to dispense the flow of the slurry as a curtain of the slurry. 1. An investment mold slurry curtain apparatus , comprising:a slurry curtain of a slurry fluid, the slurry curtain having a length and a thickness, the length substantially greater than the thickness; andan outlet, the outlet configured to dispense the slurry fluid and form the slurry curtain.2. The apparatus of claim 1 , wherein the slurry curtain comprises a flat plane.3. The apparatus of claim 1 , wherein the slurry curtain comprises a curved plane.4. The apparatus of claim 1 , wherein the length is about 5 to about 1000 times the thickness.5. The apparatus of claim 1 , wherein the length is about 20 to about 500 times the thickness.6. The apparatus of claim 1 , wherein the slurry curtain comprises a plurality of slurry curtains.7. The apparatus of claim 1 , wherein the thickness of the slurry curtain is constant.8. The apparatus of claim 1 , wherein the thickness of the slurry curtain varies along the length.9. The apparatus of claim 1 , wherein the outlet has an outlet shape claim 1 , and the outlet shape is adjustable.10. The apparatus of claim 9 , wherein the outlet shape is adjustable while the slurry curtain is being dispensed.11. An investment mold slurry coating apparatus claim 9 , comprising:a conduit configured to receive a flow of a slurry fluid; andan outlet operatively coupled to the conduit, the outlet configured to dispense the flow of ...

COOLING HOLE GEOMETRY FOR GAS TURBINE ENGINE COMPONENTS

A component for a gas turbine engine including: a wall enclosing an interior compartment of the component, the wall including an interior surface defining the interior compartment and an exterior surface opposite the interior surface; and a cooling hole extending from the interior surface to the exterior surface, the cooling hole including one or more flexures; wherein the wall increases from a first thickness to a second thickness at the cooling hole. 1. A component for a gas turbine engine , comprising:a wall enclosing an interior compartment of the component, the wall including an interior surface defining the interior compartment and an exterior surface opposite the interior surface; anda cooling hole extending from the interior surface to the exterior surface, the cooling hole including one or more flexures;wherein the wall increases from a first thickness to a second thickness at the cooling hole.2. The component of claim 1 , wherein the component is a blade for the gas turbine engine.3. The component of claim 1 , wherein the wall increases in thickness towards the interior compartment by a third thickness.4. The component of claim 1 , wherein the first thickness is between 0.002-0.050 inches (0.0508-1.27 mm).5. The component of claim 3 , wherein the third thickness is between 0.010-0.100 inches (0.254-2.54 mm).6. The component of claim 1 , wherein the one or more flexures follow at least one of a curve trajectory claim 1 , a spiral trajectory claim 1 , and a zig-zag trajectory.7. An investment casting mold for forming a component for a gas turbine engine claim 1 , comprising:a ceramic core;a ceramic shell outward from the ceramic core, the ceramic shell being separated from the ceramic core by a void; anda cooling hole feature extending from the ceramic core to the ceramic shell through the void, the cooling hole feature including one or more flexures,wherein the void increases from a first thickness to a second thickness at the cooling hole feature.8. The ...

CAST-IN FILM COOLING HOLE STRUCTURES

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 comprises a ceramic material. A shape of the extension comprises 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 comprises an ellipse. The extension is connected to the investment core body by the connection portion. 1. A core element of an investment core for use in a casting process used to produce an airfoil , the core element comprising:a investment core body comprising a ceramic material;an extension comprising a ceramic material, wherein the extension is connected to and protruding from the investment core body, wherein a shape of the extension comprises a tube with a centerline axis passing through a center of the extension, wherein a shape of a cross-section of the extension taken along a plane perpendicular to the extension centerline axis comprises an ellipse; anda connection portion comprising a ceramic material, wherein the connection portion is connected to the investment core body and to the extension, wherein the extension is connected to the investment core body by the connection portion.2. The core element of claim 1 , wherein the shape of the cross-section of the extension comprises a circle.3. The core element of claim 1 , further comprising a channel disposed through the extension claim 1 , wherein the channel comprises a centerline axis passing through a center of the channel claim 1 , wherein a shape of a cross-section of the channel taken along a plane perpendicular to the channel centerline axis comprises an ellipse.4. The core element of claim 3 , wherein the shape of the cross-section of the channel ...

CLUSTER MODEL AND SHELL FOR OBTAINING AN ACCESSORY FOR THE INDEPENDENT HANDLING OF FORMED PARTS AND ASSOCIATED METHOD

A cluster model and a shell for the production, by lost wax casting, of a plurality of turbomachine elements, are provided. The shell includes a central sprue that is fluidly connected to a casting cup for receiving molten metal; a plurality of shell elements; a plurality of bottom feed conduits for the shell elements; and a handling accessory shell that is independent of the plurality of shell elements and of their metal supply circuit, such that there is no fluid connection to the shell elements. The handling accessory shell is fluidly connected to the central sprue so as to allow top-pour casting of the handling accessory shell. 110-. (canceled)11. A cluster model , about which is intended to be formed a shell for production , by lost wax casting , of a plurality of turbomachine elements , said model having a longitudinal axis and comprising:a replica of a casting cup suitable for the injection of molten metal into the shell;a replica of a central sprue extending along the longitudinal axis, suitable for being fluidically connected to the casting cup for receiving the molten metal;a plurality of replicas of shell elements each intended for obtaining one of the turbomachine elements, each shell element including a first bottom end portion and a second top end portion;a plurality of replicas of bottom feed conduits for the shell elements, suitable for being fluidically connected to the central sprue and the second bottom end portions of the shell elements so as to allow bottom-pour casting of the shell elements; anda replica of a handling accessory shell that is independent of the plurality of shell elements and of the metal supply circuit thereof, such that there is no fluidic connection to the shell elements, the handling accessory shell being suitable for being fluidically connected to the central sprue so as to allow top-pour casting of the handling accessory shell.12. A shell for production , by lost wax casting , of a plurality of turbomachine elements , said ...

EMBEDDED HIGH DENSITY CASTING

Described herein is a golf club head having a body and a high density metal piece integrally embedded within the golf club head body, wherein a gap is disposed between the exterior surface of the high density metal piece and the exterior of the golf club head body and a method of manufacturing thereof. 1. A golf club head comprising:a club head body; anda high density metal piece integrally embedded in the club head body, the high density metal piece comprising a base portion having a first surface exposed to the exterior of the club head body, wherein an exterior surface of the club head body and the first surface of the high density metal piece form a gap disposed between them, the gap extending towards an interior of the club head body exposing a perimeter of the base portion, wherein oxidation and discoloration caused during the manufacturing process are not visible on the exposed first surface.2. The golf club head of claim 1 , wherein the gap is filled with a filler material.3. The golf club head of claim 2 , wherein the filler material is at least one of a paint claim 2 , epoxy claim 2 , rubber claim 2 , and silicone.4. The golf club head of claim 1 , wherein the high density metal piece comprises a second surface opposite the first surface claim 1 , and wherein the second surface comprises at least one protrusion extending towards the interior of the golf club head.5. The golf club head of claim 4 , wherein the second surface comprises two protrusions extending along axes that are parallel to one and other.6. The golf club head of claim 4 , wherein the at least one protrusion comprises a notch.7. The golf club of claim 6 , wherein the notch defines a cut-out region on the at least one protrusion.8. The golf club of claim 7 , wherein the notch comprises a notch length as measured along a length of the at least one protrusion.9. The golf club of claim 8 , wherein the notch length is at least 0.005 inch.10. The golf club head of claim 1 , wherein the first ...

CORE WITH THERMAL CONDUCTING CONDUIT THEREIN AND RELATED SYSTEM AND METHOD

A core for forming a casting article including a sacrificial material about the core is disclosed. The casting article is used for forming a mold for investment casting a component. The core may include a body having an external shape to form at least a section of an internal structure of the component during the investment casting; and a closed loop, core thermal conducting conduit inside a portion of the body. The closed loop, core thermal conducting conduit defines a path for a temperature controlled thermal fluid to pass through the portion of the body to control a temperature of the portion during forming of the casting article. A system may include the core and a thermal fluid controller for controlling the temperature of the thermal fluid. A related method is also disclosed. 1. A core for forming a casting article including a sacrificial material about the core , the casting article used for forming a mold for investment casting a component , the core comprising:a body having an external shape to form at least a section of an internal structure of the component during the investment casting; anda closed loop, core thermal conducting conduit inside a portion of the body, the closed loop, core thermal conducting conduit defining a path for a temperature controlled thermal fluid to pass through the portion of the body to control a temperature of the portion during forming of the casting article.2. The core of claim 1 , wherein the closed loop claim 1 , core thermal conducting conduit includes an inlet port and an outlet port claim 1 , the closed loop claim 1 , core thermal conducting conduit extending from the inlet port to the outlet port.3. The core of claim 1 , further comprising a plurality of closed loop claim 1 , core thermal conducting conduits claim 1 , each closed loop claim 1 , core thermal conducting conduit inside a different portion of the body and each defining a different path for a respective temperature controlled thermal fluid through the ...

CORE MECHANICAL INTEGRITY TESTING BY VISCOSITY MANIPULATION

A mold system for forming a casting article for investment casting in which the mechanical integrity of a ceramic core can be tested by viscosity manipulation. A method for testing a ceramic core used for an investment casting includes: positioning the ceramic core within a mold for receiving a sacrificial material fluid to form a sacrificial material on at least a portion of the ceramic core, the ceramic core having a predefined layout; during casting of the sacrificial material fluid about the ceramic core using the mold, controlling a viscosity of the sacrificial material fluid to simulate an expected viscosity of a molten metal used during a subsequent investment casting using the ceramic core; and evaluating mechanical damage to at least one region of the ceramic core caused by the casting of the sacrificial material fluid. 1. A method for testing a ceramic core used for an investment casting , the method comprising:positioning the ceramic core within a mold for receiving a sacrificial material fluid to form a sacrificial material on at least a portion of the ceramic core, the ceramic core having a predefined layout;during casting of the sacrificial material fluid about the ceramic core using the mold, controlling a viscosity of the sacrificial material fluid to simulate an expected viscosity of a molten metal used during a subsequent investment casting using the ceramic core; andevaluating mechanical damage to at least one region of the ceramic core caused by the casting of the sacrificial material fluid.2. The method of claim 1 , wherein the mechanical damage includes cracking or breaking of the ceramic core.3. The method of claim 1 , further comprising claim 1 , after the evaluating claim 1 , modifying the predefined layout of the ceramic core.4. The method of claim 3 , further comprising repeating the positioning claim 3 , viscosity controlling claim 3 , evaluating claim 3 , and modifying until the casting of the sacrificial material fluid does not damage ...

MOLD SYSTEM INCLUDING SEPARABLE, VARIABLE MOLD PORTIONS FOR FORMING CASTING ARTICLE FOR INVESTMENT CASTING

A mold system and method for forming a casting article for investment casting is disclosed. The mold system includes a mold for receiving therein a selected core chosen from a plurality of varied cores. The mold includes a plurality of separable mold portions that are coupleable together to create the mold and configured to form a sacrificial material from a sacrificial material fluid about the selected core. At least one selected separable mold portion of the plurality of separable mold portions includes a set of varied interchangeable versions of the at least one selected separable mold portion. Each varied interchangeable version of the selected separable mold portion is configured to accommodate a different core of the plurality of varied cores. A number of systems for controlling a temperature of the mold are also disclosed. 1. A mold system for forming a casting article for investment casting , the mold system comprising:a mold for receiving therein a selected core chosen from a plurality of varied cores, the mold including a plurality of separable mold portions that are coupleable together to create the mold and configured to form a sacrificial material from a sacrificial material fluid about the selected core,wherein at least one selected separable mold portion of the plurality of separable mold portions includes a set of varied interchangeable versions of the at least one selected separable mold portion, each varied interchangeable version of the selected separable mold portion configured to accommodate a different core of the plurality of varied cores.2. The mold system of claim 1 , wherein the plurality of separable mold portions include fasteners to selectively couple the plurality of separable mold portions together.3. The mold system of claim 1 , wherein each separable mold portion is additively manufactured.4. The mold system of claim 3 , wherein the additive manufacturing is selected from stereolithography and direct metal laser melting.5. The mold ...

MOLD SYSTEM INCLUDING SEPARABLE, VARIABLE MOLD PORTIONS FOR FORMING CASTING ARTICLE FOR INVESTMENT CASTING

A mold system and method for forming a casting article for investment casting is disclosed. The mold system includes a mold for receiving therein a selected core chosen from a plurality of varied cores. The mold includes a plurality of separable mold portions that are coupleable together to create the mold and configured to form a sacrificial material from a sacrificial material fluid about the selected core. At least one selected separable mold portion of the plurality of separable mold portions includes a set of varied interchangeable versions of the at least one selected separable mold portion. Each varied interchangeable version of the selected separable mold portion is configured to accommodate a different core of the plurality of varied cores. A number of systems for controlling a temperature of the mold are also disclosed. 1. A mold system for forming a casting article for investment casting , the mold system comprising:a mold for receiving therein a core, the mold including a plurality of sacrificial material fluid input zones configured to receive a sacrificial material fluid to form a sacrificial material about the core; anda sacrificial material heating system configured to heat a plurality of flows of the sacrificial material fluid to different temperatures,wherein one sacrificial material fluid input zone receives one of the plurality of flows of the sacrificial material fluid at a first temperature and another sacrificial material fluid input zone receives another of the plurality of flows of the sacrificial material fluid at a second, different temperature.2. The mold system of claim 1 , wherein the mold includes a plurality of separable mold portions that are coupleable together to create the mold and configured to form the sacrificial material from the sacrificial material fluid about the core claim 1 ,wherein each separable mold portion includes at least one sacrificial material fluid input zone.3. The mold system of claim 2 , wherein a selected ...

MOULDING DEVICE

The invention relates to a moulding device () for moulding a material around a core (), comprising a hollow moulding enclosure () suitable for receiving the core (), and means for controlling the shape of the core () in the hollow enclosure (), the control means comprising means for deforming the core (). The control means further comprise force control means and a control unit () suitable for actuating the deformation means in accordance with information provided by the force control means. 1123223218. A molding device () for molding a material around a core () , comprising a hollow molding enclosure () adapted to receive the core () , and means for controlling the shape of the core () in the hollow enclosure () , the control means comprising means for deforming the core () , the molding device () is characterized in that the control means further comprise force monitoring means and a control unit () adapted to actuate the deformation means based on information given by the force monitoring means.2162. The molding device () according to claim 1 , wherein the monitoring means comprise at least one force sensor () adapted to measure a force applied on the core ().312. The molding device () according to any of or claim 1 , wherein the deformation means allow deforming the core () along three orthogonal directions in space.41822. The molding device () according to any of to claim 1 , wherein the control unit is adapted to actuate the deformation means so that a stress in the core is minimal as long as the core is shaped in a position and a shape within predetermined manufacturing tolerances.51422. The molding device () according to any of to claim 1 , wherein the deformation means comprise support portions () on the core () serving as a stopper blocking the core ().61622. The molding device () according to any of to claim 1 , wherein the deformation means comprise movable support elements () on the core () that allow exerting pressure to deform the core ().71622. The ...

NAIL ORNAMENT

The present invention relates to a nail ornament having a base substrate and a plurality of three-dimensional ornaments attached to the base substrate in that the lower surface of the base substrate is configured to substantially conform to a nail and the plurality of ornaments are embedded in the upper surface of the base substrate. Recesses are formed in the upper surface of the base substrate and the plurality of three-dimensional ornaments fits into the recesses. The lower surface of the base substrate is curved such that the lower surface substantially conforms to a contour of a nail when placed in contact with the nail. 2. The nail ornament of wherein the lower surface is in an arc shape which substantially conforms to a circle having a diameter of about 13 mm.3. The nail ornament of wherein the lower surface is in an arc shape which substantially conforms to a circle having a diameter of about 10 mm.4. The nail ornament of wherein a depth from a bottom of the recesses to the lower surface is about 0.4˜0.6 mm.5. The nail ornament of wherein a depth from a bottom of the recesses to the lower surface is about 0.5 mm.6. The nail ornament of wherein a depth from the upper surface to the lower surface along a vertical central axis is about 2˜3 mm.7. The nail ornament of wherein a width of the nail ornament along a horizontal axis is about 6˜10 mm.8. The nail ornament of wherein a width of the nail ornament along a horizontal axis is about 6˜7 mm.9. The nail ornament of wherein the base substrate is made of Babbitt.10. The nail ornament of wherein the base substrate is made of tin-based Babbitt.11. The nail ornament of wherein the tin-based Babbitt comprises about 30˜40 weight percentage of tin.12. The nail ornament of wherein the tin-based Babbitt comprises about 35 weight percentage of tin.13. The nail ornament of wherein the base substrate is made of brass.14. The nail ornament of wherein nickel-free coating is applied to the base substrate.15. A method of ...

SELF-BONDING REFRACTORIES FOR INVESTMENT CASTING SLURRIES AND MOLDS DERIVED THEREFROM

A self-bonding refractory powder product for use in making a slurry for investment casting molds comprising a coarse refractory powder; a Nano-sized powder; and an organic polymer powder, wherein it does not require aqueous colloidal silica to produce slurries used to build investment casting molds. The Nano-sized powder comprises fumed alumina, boehmite, fumed silica, or fumed titanium oxide or combinations thereof. The coarse refractory powder comprises milled zircon, tabular alumina or fused alumina, fused silica, alumino-silicate, zirconia, and yttria or combinations thereof. The organic polymer powder comprises a cellulose-based material. 1. A self-bonding refractory powder product for use in making a slurry for investment casting molds comprising: a Nano-sized powder; and', 'an organic polymer powder., 'a coarse refractory powder;'}2. The self-bonding refractory powder product of claim 1 , wherein said coarse refractory powder comprises:aluminum oxide, zircon, mullite, alumino-silicate, zirconium oxide, yttrium oxide, fused silicon oxide, and combinations thereof.3. The self-bonding refractory powder product of claim 1 , wherein said Nano-sized powder comprises:boehmite or pseudo boehmite, aluminum oxide, silicon oxide, or titanium oxide, and combinations thereof.4. The self-bonding refractory powder product of claim 1 , wherein said organic polymer powder comprises:at least one of a cellulose-based material and a cellulose-based material combined with polyethylene glycol.5. The self-bonding refractory powder product of wherein sizes of particles of said coarse refractory powder are −325 mesh claim 1 , −200 mesh claim 1 , and −120 mesh and combinations thereof.6. The self-bonding refractory powder product of wherein said Nano-sized powder component comprises particles less than about 300 nanometers.7. The self-bonding refractory powder product of wherein claim 1 , when dispersed in deionized water claim 1 , and buffered to between 3.0 and 5.0 pH claim 1 , ...

CORE POSITIONING

A method locates and maintains a core in fixed space relationship within the interior of a shell mould. The method provides at least one pin extending into the core with at least one axial end of the pin protruding from the core. A wax pattern having an outer surface is formed by encasing the core and at least one protruding axial end of the pin in wax such that at least one protruding axial end of the pin terminates at the outer surface of the wax pattern. A shell mould is formed around the wax pattern such that, upon removal of the wax pattern, and in a subsequent casting process for production of hollow metal components, at least one protruding axial end of the pin abuts the shell mould, thus fixing the pin and maintaining a position of the core relative to the mould. The protruding axial end of the pin has an enlarged head. 1. An apparatus for locating and maintaining a core in a fixed space relationship within the interior of a shell mould , the apparatus comprising:at least one pin extending into the core with at least one axial end of the at least one pin protruding from the core, the core and the at least one protruding axial end of the at least one pin being encased within a wax pattern having an outer surface with the at least one protruding axial end of the at least one pin being flush with the outer surface of the wax pattern, and the wax pattern being encased within said shell mould, such that, upon removal of the wax pattern, and in a subsequent casting process for the production of a hollow metal component, the at least one protruding axial end of the at least one pin abuts the shell mould thus fixing the pin and maintaining a position of the core relative to the shell mould,wherein the at least one protruding axial end of the at least one pin has an enlarged head portion.2. Apparatus according to wherein the at least one pin extends all the way through the core and has two protruding axial ends each with a respective enlarged head portion.3. ...

Method and apparatus for forming sand molds via top and bottom pneumatic sand filling perpendicular to the pattern plate

A sand molding apparatus and method, whereby cope and drag portions of a sand mold are formed simultaneously via pressurized sand delivered to each side of a pattern in a perpendicular trajectory. Two opposing sand shooting passageways include a vertical inner side wall and a horizontal inner side wall extending at an angle from the vertical inner side wall. A sand shooting plate at the outlet of each sand shooting passageway includes removable and interchangeable port and cover inserts that can be arranged in custom arrays within the sand shooting plate.

Laser assisted casting and related system

Various embodiments include methods and related systems for laser-assisted casting. Some embodiments include a method including: performing laser ablation to a preliminary wax casting model to form a modified wax model including at least one additional feature absent from the wax casting substrate; coating the modified wax model to form a mold shape around the modified wax model; and removing the modified wax model to leave a casting mold including the at least one additional feature.

LASER ASSISTED CASTING OF SURFACE TEXTURE AND RELATED SYSTEM

Various embodiments include methods and related systems for laser-assisted casting. Some embodiments include a method including: performing laser ablation to a preliminary wax casting model to form a modified wax model including at least one surface texture element absent from the wax casting substrate; coating the modified wax model to form a mold shape around the modified wax model; and removing the modified wax model to leave a casting mold including the at least one surface texture element. 1. A method comprising:performing laser ablation to a preliminary wax casting model to form a modified wax model including at least one surface texture element absent from the preliminary wax casting model;coating the modified wax model to form a mold shape around the modified wax model; andremoving the modified wax model to leave a casting mold including the at least one surface texture element.2. The method of claim 1 , further comprising forming a shape from a casting material using the casting mold having the at least one surface texture element.3. The method of claim 2 , wherein the casting material includes steel or alloys including steel.4. The method of claim 2 , wherein the forming of the shape includes:pouring the casting material into the casting mold having the at least one surface texture element; andcooling the casting material to solidify the shape.5. The method of claim 1 , wherein the performing of the laser ablation includes applying an ultra-short-pulse laser to the preliminary wax casting model to directly vaporize a portion of the preliminary wax casting model claim 1 , forming the at least one surface texture element claim 1 , wherein the surface texture element has an aspect ratio of approximately 1 to approximately 10.6. The method of claim 5 , wherein the directly vaporizing includes increasing a local temperature of the portion of the preliminary wax casting model above approximately 500 degrees Celsius.7. The method of claim 6 , wherein the directly ...

LASER ASSISTED CASTING OF COOLING HOLE AND RELATED SYSTEM

Various embodiments include methods and related systems for laser-assisted casting. Some embodiments include a method including: performing laser ablation to a preliminary wax casting model to form a modified wax model including at least one cooling hole absent from the wax casting substrate; coating the modified wax model to form a mold shape around the modified wax model; and removing the modified wax model to leave a casting mold including the at least one cooling hole. 1. A method comprising:performing laser ablation to a preliminary wax casting model to form a modified wax model including at least one cooling hole absent from the preliminary wax casting model;coating the modified wax model to form a mold shape around the modified wax model; andremoving the modified wax model to leave a casting mold including the at least one cooling hole.2. The method of claim 1 , further comprising forming a shape from a casting material using the casting mold having the at least one cooling hole.3. The method of claim 2 , wherein the casting material includes steel or alloys including steel.4. The method of claim 2 , wherein the forming of the shape includes:pouring the casting material into the casting mold having the at least one cooling hole; andcooling the casting material to solidify the shape.5. The method of claim 1 , wherein the performing of the laser ablation includes applying an ultra-short-pulse laser to the preliminary wax casting model to directly vaporize a portion of the preliminary wax casting model claim 1 , forming the at least one cooling hole claim 1 , wherein the cooling hole has an aspect ratio of approximately 5 to approximately 10.6. The method of claim 5 , wherein the directly vaporizing includes increasing a local temperature of the portion of the preliminary wax casting model above approximately 500 degrees Celsius.7. The method of claim 6 , wherein the directly vaporizing includes maintaining a temperature of an adjacent portion of the preliminary ...

PROCESS CYCLE INCLUDING LASER ASSISTED CASTING AND RELATED SYSTEM

Various embodiments include methods and related systems for laser-assisted casting. Some embodiments include a method including: performing laser ablation on a preliminary wax casting model to form a modified wax model including at least one additional feature absent from the preliminary wax casting model; coating the modified wax model to form a mold shape around the modified wax model; removing the modified wax model to leave a casting mold including the at least one additional feature; forming a shape from a casting material using the casting mold having the at least one additional feature; and scanning the modified wax model to image the at least one additional feature after the performing of the laser ablation. 1. A method comprising:performing laser ablation on a preliminary wax casting model to form a modified wax model including at least one additional feature absent from the preliminary wax casting model;coating the modified wax model to form a mold shape around the modified wax model;removing the modified wax model to leave a casting mold including the at least one additional feature;forming a shape from a casting material using the casting mold having the at least one additional feature; andscanning the modified wax model to image the at least one additional feature after the performing of the laser ablation.2. The method of claim 1 , wherein the casting material includes steel or alloys including steel.3. The method of claim 1 , wherein the forming of the shape includes:pouring the casting material into the casting mold having the at least one additional feature; andcooling the casting material to solidify the shape.4. The method of claim 1 , wherein the performing of the laser ablation includes applying an ultra-short-pulse laser to the preliminary wax casting model to directly vaporize a portion of the preliminary wax casting model claim 1 , forming the at least one additional feature.5. The method of claim 4 , wherein the directly vaporizing includes ...

HYBRID COMPONENT WITH COOLING CHANNELS AND CORRESPONDING PROCESS

A component is provided and includes a core including a ceramic matrix composite material, one or more cooling channels formed about the core, an outer metal shell disposed about the core and the one or more cooling channels and a protective material between the core and the outer metal shell. The one or more cooling channels are formed about the core as an array of cooling channels in the protective material. 1. A component comprising:a core comprising a ceramic matrix composite material;one or more cooling channels formed about the core; andan outer metal shell disposed about the core and the one or more cooling channels.2. The component of claim 1 , wherein the component comprises a component of a gas turbine engine.3. The component of claim 1 , wherein the component further comprises a protective material between the core and the outer metal shell.4. A component comprising:a core comprising a ceramic matrix composite material;one or more cooling channels formed about the core;an outer metal shell disposed about the core and the one or more cooling channels; anda protective material between the core and the outer metal shell,wherein the one or more cooling channels are formed about the core as an array of cooling channels in the protective material.5. The component of claim 4 , wherein the component comprises a component of a gas turbine engine.6. The component of claim 4 , wherein the protective material is between an outer perimeter of the core and an inner perimeter of the outer metal shell.7. The component of claim 6 , wherein inner and outer perimeters of the protective material abut with the outer perimeter of the core and the inner perimeter of the outer metal shell claim 6 , respectively.8. The component of claim 4 , wherein the protective material is formed as a ring and the array of the cooling channels is ring-shaped.9. A gas turbine engine component claim 4 , comprising:a core comprising a ceramic matrix composite material;an outer metal shell ...

FOUNDRY CORE ASSEMBLY FOR MANUFACTURING A TURBOMACHINE BLADE, ASSOCIATED METHOD OF MANUFACTURING A BLADE AND ASSOCIATED BLADE

A foundry core for manufacturing a blade of a turbomachine including a tip section offset, including a core element for forming various internal cavities, the core element including a leading-edge cavity internal core, central cavity internal cores, and a trailing-edge cavity internal core. The internal core for the central cavity adjacent to the internal core for the trailing-edge cavity includes a bulge extending toward the core for the leading-edge cavity. 19-. (canceled)10. An assembly forming a foundry core for manufacturing a blade of a turbomachine including a tip section offset cooled by circulation of fluid in internal cavities , comprising:a first core element of elongated form for formation of different internal cavities; anda second core element for formation of a bath cavity, the second core element being configured to be arranged in an extension of the first core element,wherein the first core element comprises a leading edge cavity internal core, at least one central cavity internal core, and a trailing edge cavity internal core configured to respectively form, from upstream to downstream in a direction of flow of gas in the turbine, a leading edge cavity, at least one central cavity, and a trailing edge cavity of the blade, andwherein the at least one internal core of the central cavity adjacent to the internal core of the trailing edge cavity includes, in an immediate vicinity of the second core element, a bulge that extends in a direction of the core of the leading edge cavity.11. The assembly forming a foundry core according to claim 10 , wherein the internal core claim 10 , which is opposite the central cavity internal core that includes the bulge claim 10 , includes a counterform that is complementary to the bulge.12. The assembly forming a foundry core according to claim 10 , further comprising at least one linking rod that extends between the second core element and the bulge by being anchored in each other.13. The assembly forming a core ...

METHOD FOR PRODUCING A METAL BLADED ELEMENT FOR A TURBOMACHINE OF AN AIRCRAFT

The invention relates to a method for producing a metal bladed element for a turbomachine of an aircraft, said bladed element comprising at least one blade having a lower surface and an upper surface extending between a leading edge and a trailing edge of the blade, the trailing edge having to have a thickness Xl, said method comprising the steps of: a) producing the bladed element by lost-wax casting, and b) finishing the bladed element, characterised in that step b) comprises the chemical milling at least of the trailing edge of the or each blade so as to obtain said thickness X which cannot be directly obtained by step a). 11. A method for producing a metal bladed element for an aircraft turbine engine , this bladed element comprising at least one blade comprising a pressure side and a suction side extending between a leading edge and a trailing edge of the blade , the trailing edge having to have a thickness X , the method comprising the steps of:{'b': '2', 'a) producing the bladed element by lost-wax casting, the trailing edge having a thickness X during the step a),'}b) finishing the bladed element,{'b': 1', '1', '2, 'characterized in that the step b) comprises the chemical milling at least of the trailing edge of the or each blade so as to obtain said thickness X which cannot be directly obtained by the step a), the thickness X being less than the thickness X.'}21. The method according to claim 1 , wherein the thickness X is less than 1 mm claim 1 , preferably less than or equal to 0.5 mm and more preferably between 0.2 and 0.45 mm.3. The method according to claim 1 , wherein the chemical milling removes a material thickness at the surface of between 0.05 and 0.5 mm claim 1 , and more preferably between 0.05 and 0.15 mm.4. The method according to claim 1 , wherein the bladed element is made of a metal alloy based on nickel claim 1 , cobalt or chromium.5. The method according to claim 4 , wherein it comprises at least one subsequent step selected from: a step ...

Embedded High Density Casting

Described herein is a golf club head having a body and a high density metal piece integrally embedded within the golf club head body, wherein a gap is disposed between the exterior surface of the high density metal piece and the exterior of the golf club head body and a method of manufacturing thereof. 2. The method of claim 1 , further comprising the step of filling the gap with a filler material after removing the ceramic.3. The method of claim 2 , wherein the filler material is at least one of a paint claim 2 , epoxy claim 2 , rubber claim 2 , and silicone.4. The method of claim 1 , wherein the gap has a depth between 0.01 inches and 1 inches.5. The method of claim 1 , wherein the gap has a width between 0.01 inches and 1 inches.6. The method of claim 1 , wherein the high density metal piece that abuts the tool comprises a first surface exposed to the exterior of the club head claim 1 , and wherein the first surface includes at least one protrusion extending outward from the golf club head.7. The method of claim 6 , further comprising the step of removing the at least one protrusion by at least one method selecting from the group consisting of grinding claim 6 , laser removal claim 6 , machining claim 6 , and electrical discharge machining after the removal of the ceramic.8. The method of claim 6 , wherein the at least one protrusion includes a cross section which is symmetrical or non-symetrical.9. The method of claim 1 , wherein the high density metal piece comprises a first surface exposed to the exterior of the club head and a second surface opposite the first surface claim 1 , wherein the second surface comprises at least one protrusion.10. A golf club head comprising:a club head body; anda high density metal piece integrally embedded in the club head body, the high density metal piece comprising a base portion having a first surface exposed to the exterior of the club head body, wherein an exterior surface of the club head body and the first surface of the ...

Casting process to make a metal 3d product

The invention is directed to a casting process to make a metal 3D product by performing the following steps, (a) providing a form negative mould of the 3D product comprising of a plastic sheet which sheet defines at its inner side a hollow space corresponding with at least the shape of one or more of the 3D products by thermoforming using a master mould, (b) applying a layer of refractory material on the exterior of the plastic sheet of the mould to obtain a ceramic mould having a hollow space, (c) pouring molten metal into the hollow space of the ceramic mould and allowing the metal to solidify, and. (d) removing the layer of refractory material to obtain the metal 3D product.

SYSTEM AND METHOD FOR FORMING A LOW ALLOY STEEL CASTING

A method of casting a low alloy steel using a mold is disclosed. The method includes receiving the mold having a foam pattern disposed within a sand casing. The received foam pattern is coated with a permeable refractory coating and is disposed between compacted sand and the sand casing. The method further includes pouring a molten metal comprising a low alloy steel having a carbon content in a range from about 0.1 to about 0.4 percent into the mold so as to vaporize the foam pattern and remove gasification products through the permeable refractory coating, to form a low alloy steel casting. Further, the method includes removing the low alloy steel casting from the mold. 1. A method comprising:receiving a mold comprising a foam pattern provided with a permeable refractory coating, disposed within a sand casing, and compacted sand disposed between the foam pattern and the sand casing;pouring a molten metal comprising a low alloy steel having a carbon content in a range from about 0.1 to about 0.4 percent, into the mold to vaporize the foam pattern and removing a gasification product through the permeable refractory coating, to form a low alloy steel casting; andremoving the low alloy steel casting from the mold.2. The method of claim 1 , further comprising:forming the foam pattern having a cavity;preparing a permeable refractory coating material having a predefined rheology;applying the permeable refractory coating material on the foam pattern to form the permeable refractory coating on the foam pattern; anddisposing the foam pattern within the sand casing and filling unbonded sand between the foam pattern and the sand casing and compacting the unbonded sand to form the compacted sand to support the foam pattern.3. The method of claim 2 , wherein the foam pattern comprises a foam material having a bulk density in a range from about 13 to about 28 kg/m.4. The method of claim 2 , wherein the foam pattern comprises a foam material having a surface density in a range ...

Method for induction stirred, ultrasonically modified investment castings

A method for making an equiaxed investment casting. The method utilizes an ultrasonic generator to send an ultrasonic pulse into molten metal in an investment casting mold. The investment casting mold is positioned within a working zone of furnace having low output induction coils for generating a convection current in molten metal. The ultrasonic pulse separates dendrites growing from the face of the mold inward into the molten metal. Instead, equiaxed grains can nucleate within the molten metal. In addition, the ultrasonic pulse and the low output induction coils circulate the molten metal as solute is rejected from solidifying equiaxed grains. The mixing reduces the effects of segregation in the solidifying alloy and assists in nucleating equiaxed grains.

PROCESS FOR PRODUCING A COUPLER KNUCKLE AND IMPROVED COUPLER KNUCKLE

A process for producing a coupler knuckle and an improved coupler knuckle design are provided. The process produces a coupler knuckle by constructing a mold having the shape of the coupler knuckle. The mold is coated with a material that is resistant to melting at the molten melt temperatures of the molten metal used to form the knuckle. With the mold coated, the cavities in the mold interior are filled by placing an inert material therein. The molten metal used for forming the knuckle contacts the mold and consumes it, while the coating serves to provide a shape for the knuckle. 1. A method for producing a coupler knuckle comprising:forming a mold having the desired shape of the coupler knuckle to be produced, said mold having at least one cavity therein and at least one opening therein;the mold having a plurality of mold component sections, wherein said mold component sections are arrangeable together to form a representation of the shape of the coupler knuckle to be produced;wherein said at least one cavity communicates with the exterior of the mold through at least one opening;wherein said mold component sections are formed from a consumable material;arranging the plurality of mold component sections to form the shape of the coupler knuckle to be produced, the mold component sections when arranged forming said at least one cavity and forming an opening in said mold that communicates with said at least one cavity;wherein the arranged mold component sections define an interior mold surface formed therefrom, and wherein the arranged mold component sections define an exterior mold surface formed therefrom, wherein said at least one cavity is formed by the interior mold surface;applying a refractory coating the interior and the exterior mold surfaces of said arranged mold component sections to form the mold;placing said mold formed from said arranged mold component sections in a secured arrangement for receiving a first material and a second material;introducing a ...

PRODUCTION METHOD USING A VACUUM SAND CASTING MOULD

A production method for producing cast parts from metal using a sand casting mould (). The sand casting mould () is produced in this case in a moulding box () by means of a negative-pressure moulding method. According to the invention, the sand casting mould (), which is under negative pressure, in the moulding box () is first of all filled with molten metal (). The moulding box () with the sand casting mould (), which is under negative pressure therein, is then completely or partially impinged upon by a cooling fluid () and after, at the same time as, or before the cooling fluid impingement is opened at places with cooling fluid impingement. As a result of this, cooling fluid () is sucked into the sand casting mould () which is under negative pressure, as a result of which the solidifying cast part () is quenched more quickly. 11. A method for producing cast parts from metal using a sand casting mould () , comprising:{'b': 1', '2, 'producing the sand casting mould () in a moulding box () by a negative-pressure moulding method'}{'b': 1', '2, 'filling the produced sand casting mould () in the moulding box () with molten metal'}{'b': 1', '3', '4, 'cooling the sand casting mould () and the cast part () solidifying therein with a cooling fluid (),'}{'b': 1', '2', '5, 'wherein the sand casting mould (), which is under negative pressure, in the moulding box () is first filled with molten metal (),'}{'b': 2', '1', '4, 'the moulding box () with the sand casting mould (), which is under negative pressure therein, is then completely or partially impinged upon by a cooling fluid (); and'}{'b': 2', '4', '1', '3, 'the moulding box () after, at the same time as, or before the cooling fluid impingement is opened at places with cooling fluid impingement so that the cooling fluid () is sucked into the sand casting mould () which is under negative pressure and as a result quenches the solidifying cast part ().'}234. The method for producing cast parts () according to claim 1 , ...

Plated polymers with intumescent compositions and temperature indicators

A plated polymer component is disclosed. The plated polymer component may comprise a polymer support, a metal plating deposited on a surface of the polymer support, and at least one flame-retardant additive included in the polymer support. In another aspect, the plated polymer component may comprise a polymer substrate, a metal plating deposited on a surface of the polymer substrate, and a temperature-indicating coating applied to at least one of of the polymer substrate.

IMPROVED METHOD FOR MANUFACTURING A CERAMIC CORE FOR MANUFACTURING TURBOMACHINE VANES

A method for manufacturing a ceramic core blank intended for the manufacture of hollow turbomachine blades using the technique of lost wax casting, the blank being manufactured by additive manufacture and comprising at least one first part intended to form the cavities of the hollow blades and at least one second part configured to allow the positioning of the core in a wax mold, the second part and the first part being positioned and held with respect to one another by means of a junction portion interposed between the first part and the second part, at least one through orifice extending through the second part, the junction portion and the first part, a first end of the through orifice opening to an outer face of the second part, and a second end of the through orifice opening to an outer face of the first part. 1. A method for manufacturing a ceramic core blank for the manufacture of hollow turbomachine blades using the technique of lost wax casting , the blank being manufactured by additive manufacturing and comprising:at least one first part for forming the cavities of the hollow blades,at least one second part configured to allow the positioning of the core in a wax mold, the second part and the first part being positioned and held with respect to one another by means of a temporary junction portion interposed between the first part and the second part,at least one through orifice extending through the second part, the temporary junction portion and the first part, a first end of the through orifice opening to an outer face of the second part, and a second end of the through orifice opening to an outer face of the first part.2. The method according to claim 1 , wherein the temporary junction portion comprises a passage putting into fluid communication the through orifice and a space outside the core blank.3. The method according to claim 1 , wherein the through orifice comprises a first rectilinear portion extending from the first end claim 1 , and a second ...

METHOD OF PRODUCING A METAL FORM CONTAINING DISPERSED AEROGEL PARTICLES IMPREGNATED WITH POLYMERS

A method of producing a metal form containing dispersed aerogel particles impregnated with polymers comprising a method of impregnating an aerogel with polymers, placing the aerogel impregnated with polymers within a dissolved polymer, cooling the dissolved polymer to create a polymer form with dispersed aerogel particles impregnated with polymers, adding molten metal to the polymer form, vaporizing the polymer form, replacing the polymer form with molten metal, and cooling the molten metal to yield a metal form containing dispersed aerogel particles impregnated with polymers. Dispersing the aerogel particles impregnated with polymers within the polymer form prior to adding molten metal allows the aerogel particles to be fully dispersed throughout the metal form. 1. A method of producing a metal form containing dispersed aerogel particles impregnated with polymers , said method comprising the steps of;(a) mixing at least one solvent to produce a homogeneous mixture,(b) stirring a catalyst into the homogenous mixture to produce a liquid containing solid nanoparticles,(c) mixing the liquid containing solid nanoparticles with a hydrocarbon to create an emulsion,(d) stirring the emulsion until gelation occurs,(e) removing the hydrocarbon from the emulsion with a first dissolving agent to produce a plurality of aerogel particles containing pores,(f) dissolving a polymer in a second dissolving agent to create a dissolved polymer,(g) mixing the plurality of aerogel particles with an alcohol and the dissolved polymer to produce a first mixture,(h) dilating the pores of the aerogel particles within the first mixture,(i) placing the first mixture into a first mold,(j) freezing the first mixture within the first mold creating a solid form,(k) removing the solid form from the first mold,(l) separating the solid form into a plurality of solid particles,(m) placing the solid particles into a chemical bath,(n) replacing the first and second dissolving agent within the solid ...

Improved method for manufacturing a shell mold for production by lost-wax casting of bladed elements of an aircraft turbine engine

A method for manufacturing a shell mold for the production by lost-wax casting of bladed elements ( 1 ) of an aircraft turbine engine, including the following steps: creating an assembly ( 200 ) including a wax pattern ( 100 ) as well as a device for forming a cup for pouring metal ( 32 b ) and having an end surface ( 40 a ); depositing a hot wax coating layer on at least one portion of the end surface ( 40 a ); forming the shell mold around the assembly ( 200 ). In addition, the method includes, between steps b) and c), the implementation of a step of structuring the coating layer intended for reinforcing the adhesion between the layer ( 46 ) and the shell mold, and including the production of recesses ( 62 ) and projections ( 60 ) on the still-malleable coating layer.

Castings and Manufacture Methods

A method for casting an article comprises a first region and a second region. The method comprises casting an alloy in a shell, the shell having a casting core protruding from a first metal piece; and deshelling and decoring to remove the shell and core and leave the first region formed by the first piece and the second region formed by the casted alloy. 160602828228081. A method for casting an article (;-) comprising a first region (;-) and a second region (;) , the method comprising:{'b': 290', '232', '220, 'casting an alloy in a shell (), the shell having a casting core () protruding from a first metal piece (); and'}deshelling and decoring to remove the shell and core and leave the first metal region formed by the first piece and the second region formed by the casted alloy.2. The method of wherein:{'b': '90', 'the decoring leaves one or more passageways () spanning between the first region and the second region.'}3. The method of wherein:{'b': 232', '226, 'the casting core () is interfittingly mated with passageways () in the first metal piece.'}4. The method of further comprising:adhesive bonding the casting core to the first metal piece.5. The method of wherein:{'b': '61', 'the first region forms a first portion of an airfoil () and the second region forms a second region of said airfoil.'}6. The method of wherein:the first region and the second region have different compositions of nickel-based superalloy.7. The method of wherein:the first region and the second region have a shared crystalline structure.8. The method of further comprising: [{'b': 170', '122, 'casting the first metal piece in a first shell () containing a first casting core (); and'}, 'at least partially deshelling and decoring the first metal piece., 'forming the first metal piece by9. The method of further comprising:mating the casting core to the first metal piece;placing the first metal piece and the casting core in a die;overmolding a sacrificial pattern material to the casting core in ...

Interlocked plated polymers

A plated polymer component is disclosed. The plated polymer component may comprise a polymer substrate having an outer surface, a metal plating attached to the outer surface of the polymer substrate, and at least one interlocking feature connecting the polymer substrate and the metal plating. The interlocking feature may improve the interfacial bond strength between the polymer substrate and the metal plating.

Method for producing a pattern for lost pattern casting

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

Method of Manufacturing Golf Club Head Having Stress-Reducing Features

A method of manufacturing a golf club head comprising a plurality of stiffening members proximate the face, and particularly solid rods or a plate with one or more cutouts, is disclosed herein. The method comprises the steps of preparing a wax of a golf club head body, the body comprising at least one through-holes, a hollow interior, and at least one receiving pocket, preparing waxes of one or more stiffening members, inserting the wax of the stiffening members into the through-hole and seating its opposite end in the receiving pocket, bonding each of the stiffening members to the body with an adhesive material to form a combined wax mold, and casting a golf club head from the combined wax mold.

Cooling Device and Method for Cooling a Component Produced in a Lost Foam Casting Method

A cooling device is provided for cooling a component produced in a lost foam casting method by way of an EPS model. The cooling device has at least one cooling element which can be disposed flat on at least one region of the EPS model. The at least one cooling element can be fixed in a materially bonded and/or non-positive manner to the at least one region of the EPS model. A method for cooling the component produced in the lost foam casting method by way of the EPS model using the cooling element is provided.

Method for producing coding surfaces from a blank

A method for coding components of a locking system which are used to code a key and a female lock part. The coding components may be formed integrally with the key and female lock part or be provided as coding discs that are then affixed to non-coded bodies used for the key and female lock part. A blank of an easily machinable preliminary material is separated into two coding parts with a separation cut that simultaneously creates a coding surface on each coding part. These coding parts serve as the model to mold the coding components in a lost-wax process. Each coding part is encased in a material that forms a mold shell. The coding part is then melted or gasified and escapes from the mold shell, which now has a mold cavity that is then cast with the final material to be used for the coding components.

INTEGRATED CASTING CORE-SHELL STRUCTURE WITH PRINTED TUBES FOR MAKING CAST COMPONENT

The present disclosure generally relates to integrated core-shell investment casting molds that provide filament structures corresponding to cooling hole patterns on the surface of the turbine blade or stator vane, which provide a leaching pathway for the core portion after metal casting. The invention also relates to core filaments that can be used to supplement the leaching pathway, for example in a core tip portion of the mold. 2. The method of claim 1 , wherein the process comprises claim 1 , after step (d) claim 1 , a step (e) comprising pouring a liquid metal into a casting mold and solidifying the liquid metal to form the cast component.3. The method of claim 2 , wherein the process comprises claim 2 , after step (e) claim 2 , a step (f) comprising removing the mold from the cast component.4. The method of claim 3 , wherein removing the mold from the cast component comprises a combination of mechanical force and chemical leaching.5. The method of claim 1 , wherein the outer diameter of the filament has a cross sectional area ranging from 0.01 to 2 mm.6. The method of claim 1 , wherein the filament hollow tube has an inner diameter cross-sectional area that is at least 50% of the cross sectional area of the outer diameter of the filament.7. The method of claim 1 , wherein the core portion is defined by a core hollow tube structure.8. The method of claim 1 , wherein the core hollow tube structure has an inner diameter cross-sectional area that is at least 80% of the cross sectional area of the outer diameter of the core portion.9. A method of preparing a cast component comprising:(a) pouring a liquid metal into a ceramic casting mold and solidifying the liquid metal to form the cast component, the ceramic casting mold comprising:(1) a core portion and a shell portion with at least one cavity between the core portion and the shell portion, the cavity adapted to define the shape of a cast component upon casting and removal of the ceramic mold, and(2) a plurality ...

INTEGRATED CASTING CORE-SHELL STRUCTURE WITH FLOATING TIP PLENUM

The present disclosure generally relates to integrated core-shell investment casting molds including a main core portion, a core tip portion, and a shell portion with at least one cavity between the core portion and the shell portion. The cavity defines the shape of a cast component upon casting and removal of the ceramic mold. These molds also provide filament structures corresponding to cooling hole patterns in the surface of the turbine blade or the stator vane, which provide a leaching pathway for the core portion after metal casting. At least two ceramic tip filaments connect the core tip portion and the shell portion and eliminate the need for tip pins or a shell lock to hold the tip plenum core in place during casting. The invention also relates to core filaments that can be used to supplement the leaching pathway, for example in a core tip portion of the mold. 1. A method for fabricating a ceramic mold , comprising:(a) contacting a cured portion of a workpiece with a liquid ceramic photopolymer;(b) irradiating a portion of the liquid ceramic photopolymer adjacent to the cured portion through a window contacting the liquid ceramic photopolymer;(c) removing the workpiece from the uncured liquid ceramic photopolymer; and(d) repeating steps (a)-(c) until a ceramic mold is formed, the ceramic mold comprising a main core portion, a core tip portion, and a shell portion with at least one cavity between the core portion and the shell portion, the cavity adapted to define the shape of a cast component upon casting and removal of the ceramic mold, and at least one ceramic tip filament connecting the core tip portion and the shell portion.2. The method of claim 1 , wherein the process comprises claim 1 , after step (d) claim 1 , a step (e) comprising pouring a liquid metal into a casting mold and solidifying the liquid metal to form the cast component.3. The method of claim 2 , wherein the process comprises claim 2 , after step (e) claim 2 , a step (f) comprising ...

INTEGRATED CASTING CORE-SHELL STRUCTURE

The present disclosure generally relates to integrated core-shell investment casting molds that provide a filament structure corresponding to a cooling hole pattern in the surface of the turbine blade or stator vane, which provide a leaching pathway for the core portion after metal casting. The invention also relates to core filaments that can be used to supplement the leaching pathway, for example in a core tip portion of the mold. 1. A method for fabricating a ceramic mold , comprising:(a) contacting a cured portion of a workpiece with a liquid ceramic photopolymer;(b) irradiating a portion of the liquid ceramic photopolymer adjacent to the cured portion through a window contacting the liquid ceramic photopolymer;(c) removing the workpiece from the uncured liquid ceramic photopolymer; and(d) repeating steps (a)-(c) until a ceramic mold is formed, the ceramic mold comprising a core portion and a shell portion with at least one cavity between the core portion and the shell portion, the cavity adapted to define the shape of a cast component upon casting and removal of the ceramic mold.2. The method of claim 1 , wherein the process comprises claim 1 , after step (d) claim 1 , a step (e) comprising pouring a liquid metal into a casting mold and solidifying the liquid metal to form the cast component.3. The method of claim 2 , wherein the process comprises claim 2 , after step (e) claim 2 , a step (f) comprising removing the mold from the cast component.4. The method of claim 3 , wherein removing the mold from the cast component comprises a combination of mechanical force and chemical leaching.5. The method of claim 4 , wherein the mold from the cast component is removed by chemical leaching in an alkaline bath.6. The method of claim 1 , wherein the ceramic mold comprises a plurality of filaments joining the core portion and shell portion claim 1 , the filaments adapted to define a plurality of holes in the cast component upon removal of the mold and each filament ...