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.

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.

The invention relates to a refractory coating composition for producing mold coatings on non-permanent molds or on cores for the casting of iron and steel, comprising a) an alkali metal salt or alkaline earth metal salt of carbonic acid and/or an alkali metal salt or alkaline earth metal salt of diphosphoric acid, b) a carrier liquid and c) refractory materials.

The invention relates to a refractory coating composition for producing mold coatings on non-permanent molds or on cores for the casting of iron and steel, comprising a) an alkali metal salt or alkaline earth metal salt of carbonic acid and/or an alkali metal salt or alkaline earth metal salt of diphosphoric acid, b) a carrier liquid and c) refractory materials.

A method of making an airfoil includes making a refractory metal core that defines an interior of the airfoil by a tomo-lithographic process, making a mold that defines an exterior of the airfoil, inserting the refractory metal core into the mold, and pouring an airfoil material between the refractory metal core and the mold to cast the airfoil.

A method of making an airfoil includes making a refractory metal core that defines an interior of the airfoil by a tomo-lithographic process, making a mold that defines an exterior of the airfoil, inserting the refractory metal core into the mold, and pouring an airfoil material between the refractory metal core and the mold to cast the airfoil.

A method of making a composite core includes forming first and second cores of refractory metal and ceramic material. Each of the first and second cores is formed with two layers of a material. The layers are bonded together to form a laminate master pattern, and a flexible mold is formed around the pattern. The pattern is removed from the flexible mold, and slurry material, either pulverulent refractory metal material or ceramic material, is poured into the flexible mold. The slurry material is sintered to form each core. The first core is used as an insert while making the second core to create a final composite core.

A method of making a composite core includes forming first and second cores of refractory metal and ceramic material. Each of the first and second cores is formed with two layers of a material. The layers are bonded together to form a laminate master pattern, and a flexible mold is formed around the pattern. The pattern is removed from the flexible mold, and slurry material, either pulverulent refractory metal material or ceramic material, is poured into the flexible mold. The slurry material is sintered to form each core. The first core is used as an insert while making the second core to create a final composite core.

What is described is the use of a composition containing one or more formaldehyde scavengers for production of a coating on a main body of a mold or core for metal casting that emits formaldehyde when heated, wherein the coating forms a surface of the mold or core that comes into contact with a metal melt in the casting operation.

What is described is the use of a composition containing one or more formaldehyde scavengers for production of a coating on a main body of a mold or core for metal casting that emits formaldehyde when heated, wherein the coating forms a surface of the mold or core that comes into contact with a metal melt in the casting operation.