A manufacturing method uses layered slabs to create a final pattern for a mold or for creating the mold itself. The method includes: preparing a desired number of slabs including a first slab and a second slab; machining the first slab; machining the second slab; and after the second slab is coupled to the first slab, repeating the machining step for each additional slab included in the desired number of slabs to form the final pattern or mold.

An end or intermediate casing for a combustion turbine engines includes prefabricated vanes of a first metal. Ends of the prefabricated vanes are then embedded within cast-in place inner and outer, annular-shaped ring castings, formed from a second metal having a lower melting point than the first metal. The respective ends of the prefabricated vanes include first and second shanks, with respective first and second surface features that are oriented transverse to the central axis of the vane are encapsulated in the molten second metal during the inner and outer ring casting. Once the castings harden, the first and second surface features, such as for example circumferential fillets projecting outwardly from the airfoil portion of the vane, inhibit separation of the vanes from the respective inner and outer rings.

An end or intermediate casing for a combustion turbine engines includes prefabricated vanes of a first metal. Ends of the prefabricated vanes are then embedded within cast-in place inner and outer, annular-shaped ring castings, formed from a second metal having a lower melting point than the first metal. The respective ends of the prefabricated vanes include first and second shanks, with respective first and second surface features that are oriented transverse to the central axis of the vane are encapsulated in the molten second metal during the inner and outer ring casting. Once the castings harden, the first and second surface features, such as for example circumferential fillets projecting outwardly from the airfoil portion of the vane, inhibit separation of the vanes from the respective inner and outer rings.

A foundry mix includes a major amount of a foundry aggregate and an effective binding amount of a binder system. The binder system cures in the presence of sulfur dioxide and a free radical initiator. The binder system may include (1) 10 to 70 parts by weight of an epoxy novolac resin; (2) 0.5 to 10 parts by weight of resorcinol; (3) 20 to 70 parts by weight of a monomeric or polymeric acrylate; and (4) an effective amount of a free radical initiator. Notably, (1), (2), (3) and (4) are separate components or mixed with another of said components, provided (4) is not mixed with (3), where said parts by weight are based upon 100 parts of the binder system.

A foundry mix includes a major amount of a foundry aggregate and an effective binding amount of a binder system. The binder system cures in the presence of sulfur dioxide and a free radical initiator. The binder system may include (1) 10 to 70 parts by weight of an epoxy novolac resin; (2) 0.5 to 10 parts by weight of resorcinol; (3) 20 to 70 parts by weight of a monomeric or polymeric acrylate; and (4) an effective amount of a free radical initiator. Notably, (1), (2), (3) and (4) are separate components or mixed with another of said components, provided (4) is not mixed with (3), where said parts by weight are based upon 100 parts of the binder system.

Disclosed is a 3D printer 10 having a coater 30 and a coater cleaning device 50. The coater 30 has a container 32 defining an inner cavity 34 for receiving particulate construction material and an output region 36 for outputting the particulate construction material. The coater cleaning device 50 has a cleaning web 52. The coater cleaning device 50 and the coater 30 are configured to move the output region 36 and/or the cleaning web 52 relative to each other for wiping the output region 36 by means of the cleaning web 52.

A foundry mix includes a major amount of a foundry aggregate and an effective binding amount of a binder system. The foundry binder system cures in the presence of sulfur dioxide and a free radical initiator. The binder system may include (1) 10 to 70 parts by weight of an epoxy novolac resin; (2) 0.5 to 10 parts by weight of resorcinol; (3) 20 to 70 parts by weight of a monomeric or polymeric acrylate; and (4) an effective amount of a free radical initiator. Notably, (1), (2), (3) and (4) are separate components or mixed with another of said components, provided (4) is not mixed with (3) until a foundry mix is to be created, where said parts by weight are based upon 100 parts of the binder system.

A foundry mix includes a major amount of a foundry aggregate and an effective binding amount of a binder system. The foundry binder system cures in the presence of sulfur dioxide and a free radical initiator. The binder system may include (1) 10 to 70 parts by weight of an epoxy novolac resin; (2) 0.5 to 10 parts by weight of resorcinol; (3) 20 to 70 parts by weight of a monomeric or polymeric acrylate; and (4) an effective amount of a free radical initiator. Notably, (1), (2), (3) and (4) are separate components or mixed with another of said components, provided (4) is not mixed with (3) until a foundry mix is to be created, where said parts by weight are based upon 100 parts of the binder system.

A method of producing a parallel spiral core for casting a housing includes designing a half cylinder body in a model based on a desired shape of the housing, adding parallel spiral features to the body in the model, and producing data of the model based on the desired shape of the housing with the parallel spiral features. The data is then loaded into a machining tool, which then machines a pattern of the parallel spiral core out of material. The method also includes casting the parallel spiral core from the pattern such that the parallel spiral core comprises a core body and a parallel spiral formed on the core body, the parallel spiral winding circumferentially about the core body from a first end to a second end of the core body.

A method of producing a parallel spiral core for casting a housing includes designing a half cylinder body in a model based on a desired shape of the housing, adding parallel spiral features to the body in the model, and producing data of the model based on the desired shape of the housing with the parallel spiral features. The data is then loaded into a machining tool, which then machines a pattern of the parallel spiral core out of material. The method also includes casting the parallel spiral core from the pattern such that the parallel spiral core comprises a core body and a parallel spiral formed on the core body, the parallel spiral winding circumferentially about the core body from a first end to a second end of the core body.