A method of forming a component having an internal passage defined therein is provided. The method includes positioning a jacketed core with respect to a mold. The jacketed core includes a hollow structure formed at least partially by an additive manufacturing process, and an inner core disposed within the hollow structure. The method also includes introducing a component material in a molten state into a cavity of the mold, and cooling the component material in the cavity to form the component. The inner core is positioned to define the internal passage within the component.

This invention relates to lost cores for use high pressure die casting, the cores preferably comprising a water-soluble synthetic ceramic aggregate having an appropriate strength and tolerance for various casting pressures and temperatures, an inorganic binder comprising sodium silicate, an additive comprising particulate amorphous silicon dioxide, and a refractory coating, wherein the cores have the capacity to be removed from a casting by dissolution with water.

A method of preparing a casting article for manufacturing a gas turbine engine part according to an exemplary aspect of the present disclosure includes communicating a powdered material to an additive manufacturing system, the powdered material including at least one of a silica material, an alumina material, and a refractory metal material. The method includes using the additive manufacturing system to manufacture a casting article layer by layer, the casting article including a plurality of circuit forming portions, at least one of the circuit forming portions including an interior channel that establishes a hollow opening through the circuit forming portion.

A method of preparing a casting article for manufacturing a gas turbine engine part according to an exemplary aspect of the present disclosure includes communicating a powdered material to an additive manufacturing system, the powdered material including at least one of a silica material, an alumina material, and a refractory metal material. The method includes using the additive manufacturing system to manufacture a casting article layer by layer, the casting article including a plurality of circuit forming portions, at least one of the circuit forming portions including an interior channel that establishes a hollow opening through the circuit forming portion.

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 and device for retaining position of a consumable core during composite article manufacturing is taught herein by inserting a consumable core having a consumable core body and a plurality of retention artifacts into a composite precursor hollow feature of a composite precursor structure. Then positioning the consumable core such that the plurality of retention artifacts projecting from the consumable core exterior surface at least partially engage with a substantially spatially replicate surface geometry in the composite precursor hollow feature. The consumable core is then consumed as a soluble infiltrant to form a composite article.

A method and device for retaining position of a consumable core during composite article manufacturing is taught herein by inserting a consumable core having a consumable core body and a plurality of retention artifacts into a composite precursor hollow feature of a composite precursor structure. Then positioning the consumable core such that the plurality of retention artifacts projecting from the consumable core exterior surface at least partially engage with a substantially spatially replicate surface geometry in the composite precursor hollow feature. The consumable core is then consumed as a soluble infiltrant to form a composite article.