One or more techniques and/or systems are disclosed for producing beneficial re-use sand from foundry sand. Foundry sand can be collected from a mold making operation, and/or from the casting removal and cleaning process. The collected sand product can be cleaned and separated into a clay and carbon mixture, and a beneficial re-use sand. The collected sand product can be cleaned by mixing with water, and subjecting the resulting mix to a hydrocyclone at appropriate flow rates. The hydrocyclone can separate the mix into a carbon, clay and water mix for re-use, and a wet sand mix. Water can be separated from the wet sand and reused, and the resulting sand can be used as beneficial re-use sand.

One or more techniques and/or systems are disclosed for producing beneficial re-use sand from foundry sand. Foundry sand can be collected from a mold making operation, and/or from the casting removal and cleaning process. The collected sand product can be cleaned and separated into a clay and carbon mixture, and a beneficial re-use sand. The collected sand product can be cleaned by mixing with water, and subjecting the resulting mix to a hydrocyclone at appropriate flow rates. The hydrocyclone can separate the mix into a carbon, clay and water mix for re-use, and a wet sand mix. Water can be separated from the wet sand and reused, and the resulting sand can be used as beneficial re-use sand.

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 core (1) for producing castings (100) in a modular mold; each casting (100) having at least one thermally activatable portion (102) shaped so that it can face a heat source (HS); each casting (100) having at least one duct (106) contained inside the portion (102); the duct (106) being fluid tight so that a fluid can flow through it; the core (1) having a suitable shape to form, in negative, the duct (106); the core (1) including at least one insert (20)(20)(20) shaped so as to define at least two passages (200)(200) for the fluid inside the duct (106).

A core (1) for producing castings (100) in a modular mold; each casting (100) having at least one thermally activatable portion (102) shaped so that it can face a heat source (HS); each casting (100) having at least one duct (106) contained inside the portion (102); the duct (106) being fluid tight so that a fluid can flow through it; the core (1) having a suitable shape to form, in negative, the duct (106); the core (1) including at least one insert (20)(20)(20) shaped so as to define at least two passages (200)(200) for the fluid inside the duct (106).

A casting ceramic core includes a ceramic structure having at least one through hole and a plurality of features extending from a main ceramic body. The ceramic body defines a negative space for a casting and a plurality of aligned fibers extending a substantial length of at least one casting feature.

A casting ceramic core includes a ceramic structure having at least one through hole and a plurality of features extending from a main ceramic body. The ceramic body defines a negative space for a casting and a plurality of aligned fibers extending a substantial length of at least one casting feature.

One or more techniques and/or systems are disclosed for producing beneficial re-use sand from foundry sand. Foundry sand can be collected from a mold making operation, and/or from the casting removal and cleaning process. The collected sand product can be cleaned and separated into a clay and carbon mixture, and a beneficial re-use sand. The collected sand product can be cleaned by mixing with water, and subjecting the resulting mix to a hydrocyclone at appropriate flow rates. The hydrocyclone can separate the mix into a carbon, clay and water mix for re-use, and a wet sand mix. Water can be separated from the wet sand and reused, and the resulting sand can be used as beneficial re-use sand.

One or more techniques and/or systems are disclosed for producing beneficial re-use sand from foundry sand. Foundry sand can be collected from a mold making operation, and/or from the casting removal and cleaning process. The collected sand product can be cleaned and separated into a clay and carbon mixture, and a beneficial re-use sand. The collected sand product can be cleaned by mixing with water, and subjecting the resulting mix to a hydrocyclone at appropriate flow rates. The hydrocyclone can separate the mix into a carbon, clay and water mix for re-use, and a wet sand mix. Water can be separated from the wet sand and reused, and the resulting sand can be used as beneficial re-use sand.

A method of fabricating a two-component blade for a gas turbine engine, the method including in succession: obtaining a blade profile made of ceramic material having a hole passing right through the blade profile in its length direction so as to form a longitudinal channel opening out into a top cavity; positioning and maintaining the blade profile in a mold so as to form a bottom cavity communicating with the channel of the blade profile; casting molten metal into the blade profile so as to fill the top and bottom cavities and the channel interconnecting them; and cooling the metal so that the shrinkage of the metal cooled in the top and bottom cavities leads to the ceramic of the blade profile being subjected to compression prestress.