A method of fabricating a casting is provided. The method includes creating a mixture of ceramic powder and a binder, pouring the mixture around sacrificial patterns, executing a first thermal treatment to set the mixture into a solid mold without damaging the sacrificial patterns, executing a second thermal treatment to remove the sacrificial patterns without removing any of the binder from the solid mold, executing at least one of a third thermal treatment and a chemical treatment to remove a quantity of the binder to transform the solid mold into a solid breakaway mold and pouring molten metallic material into the solid breakaway mold.

A casting method for titanium and titanium alloys, the casting method including obtaining an investment casting mold composition having calcium aluminate and aluminum oxide, the calcium aluminate combined with a liquid to produce a slurry of calcium aluminate, and wherein the solids in the final calcium aluminate/liquid mixture with large scale alumina is about 71% to about 90%. The method further includes pouring the investment casting mold composition into a vessel containing a fugitive pattern, curing the investment casting mold composition to form a mold, removing the fugitive pattern from the mold, firing the mold, preheating the mold to a mold casting temperature, pouring molten titanium or titanium alloy into the preheated mold, solidifying the molten titanium or titanium alloy and forming a solidified titanium or titanium alloy casting, and removing the solidified titanium or titanium alloy casting from the mold.

A casting method for titanium and titanium alloys, the casting method including obtaining an investment casting mold composition having calcium aluminate and aluminum oxide, the calcium aluminate combined with a liquid to produce a slurry of calcium aluminate, and wherein the solids in the final calcium aluminate/liquid mixture with large scale alumina is about 71% to about 90%. The method further includes pouring the investment casting mold composition into a vessel containing a fugitive pattern, curing the investment casting mold composition to form a mold, removing the fugitive pattern from the mold, firing the mold, preheating the mold to a mold casting temperature, pouring molten titanium or titanium alloy into the preheated mold, solidifying the molten titanium or titanium alloy and forming a solidified titanium or titanium alloy casting, and removing the solidified titanium or titanium alloy casting from the mold.

A complex cast component of an internal combustion engine, in particular a crankshaft or a camshaft, has a longitudinal axis, a plurality of regions, along the longitudinal axis, and a first cavity. Each of the plurality of regions has a certain cool-down rate during a solidification process of a casting process. The first cavity is arranged in a first region of the plurality of regions and has a volume that depends on a first cool-down rate of the first region. In this way, a material thickness in the first region likewise depends on the first cool-down rate.

A complex cast component of an internal combustion engine, in particular a crankshaft or a camshaft, has a longitudinal axis, a plurality of regions, along the longitudinal axis, and a first cavity. Each of the plurality of regions has a certain cool-down rate during a solidification process of a casting process. The first cavity is arranged in a first region of the plurality of regions and has a volume that depends on a first cool-down rate of the first region. In this way, a material thickness in the first region likewise depends on the first cool-down rate.

A vermiculite core for a vehicle may include vermiculite and pearlstone, an aluminum component for the vehicle may be manufactured using the vermiculite core including the vermiculite and the pearlstone, and a method for manufacturing the vermiculite core for the vehicle may include mixing the vermiculite and the pearlstone, injecting a mixture of the vermiculite and the pearlstone into a mold, and pressing the mixture using a presser.

A vermiculite core for a vehicle may include vermiculite and pearlstone, an aluminum component for the vehicle may be manufactured using the vermiculite core including the vermiculite and the pearlstone, and a method for manufacturing the vermiculite core for the vehicle may include mixing the vermiculite and the pearlstone, injecting a mixture of the vermiculite and the pearlstone into a mold, and pressing the mixture using a presser.

The subject matter of the invention is mold material mixtures for producing molds or cores for metal casting, consisting of at least one refractory base mold material, a binder and an additive based on factice. The invention also relates to a component system, a method for producing molds and cores using the mold material mixtures or the component system respectively, and to molds and cores produced by said method.

A method for forming a mold for casting a titanium-containing article, the method including combining calcium aluminate with a liquid to produce an initial slurry of calcium aluminate and adding oxide particles into the initial slurry to create a final slurry. The method further includes introducing the final slurry into a mold cavity that contains a fugitive pattern and allowing the final slurry to cure in the mold cavity to form a mold of a titanium-containing article.

A method for forming a mold for casting a titanium-containing article, the method including combining calcium aluminate with a liquid to produce an initial slurry of calcium aluminate and adding oxide particles into the initial slurry to create a final slurry. The method further includes introducing the final slurry into a mold cavity that contains a fugitive pattern and allowing the final slurry to cure in the mold cavity to form a mold of a titanium-containing article.