A method for manufacturing a roll mantle or roll body for a roll line of a continuous casting apparatus that has a shaft includes casting a metal to form the roll mantle or roll body such that the roll mantle or roll body includes at least one internal channel. The roll mantle or roll body has a first end region, a second end region and a central region between the first end region and the second end region, the central region extending along at least 50% of a length of the roll mantle or roll body, and the internal channel may be formed in the central region. The internal channel may also include a pattern or projection.

Methods of manufacturing or repairing a turbine blade or vane are described. The airfoil portions of these turbine components are typically manufactured by casting in a ceramic mold, and a surface made up of the cast airfoil and at the least the ceramic core serves as a build surface for a subsequent process of additively manufacturing the tip portions. The build surface is created by removing a top portion of the airfoil and the core, or by placing an ultra-thin shim on top of the airfoil and the core. The overhang projected by the shim is subsequently removed. These methods are not limited to turbine engine applications, but can be applied to any metallic object that can benefit from casting and additive manufacturing processes. The present disclosure also relates to finished and intermediate products prepared by these methods.

Methods of manufacturing or repairing a turbine blade or vane are described. The airfoil portions of these turbine components are typically manufactured by casting in a ceramic mold, and a surface made up of the cast airfoil and at the least the ceramic core serves as a build surface for a subsequent process of additively manufacturing the tip portions. The build surface is created by removing a top portion of the airfoil and the core, or by placing an ultra-thin shim on top of the airfoil and the core. The overhang projected by the shim is subsequently removed. These methods are not limited to turbine engine applications, but can be applied to any metallic object that can benefit from casting and additive manufacturing processes. The present disclosure also relates to finished and intermediate products prepared by these methods.

A process for casting aluminum alloy parts is disclosed. The process includes the steps as follows: raising a liquid aluminum alloy; filling a mold; increasing pressure; solidifying formed by at least two stages of different pressure settings; and relieving pressure.

Disclosed is a lost-wax method of casting a product, having steps of: attaching temperature control elements to a wax assembly; encasing the wax assembly and the temperature control elements in a ceramic mold; removing the wax assembly from the ceramic mold; filling the ceramic mold with molten material to form a cast part within the ceramic mold; and separating the ceramic mold and the cast part from each other.

A method for producing a piston for an internal combustion engine may include producing a piston upper part including a piston top, at least parts of a ring section, and at least part of a cooling channel, producing a piston lower part and closing the part of the cooling channel arranged in the piston upper part via an additive method, and finish-machining the piston. Finish-machining the piston may include producing at least one annular groove in a ring support for receiving a piston ring.

A method for producing a piston for an internal combustion engine may include producing a piston upper part including a piston top, at least parts of a ring section, and at least part of a cooling channel, producing a piston lower part and closing the part of the cooling channel arranged in the piston upper part via an additive method, and finish-machining the piston. Finish-machining the piston may include producing at least one annular groove in a ring support for receiving a piston ring.

A three-dimensional metallic foam is fabricated with an active oxide material for use as an anode for lithium batteries. The porous metal foam, which can be fabricated by a freeze-casting process, is used as the anode current collector of the lithium battery. The porous metal foam can be heat-treated to form an active oxide material to form on the surface of the metal foam. The oxide material acts as the three-dimensional active material that reacts with lithium ions during charging and discharging.

A three-dimensional metallic foam is fabricated with an active oxide material for use as an anode for lithium batteries. The porous metal foam, which can be fabricated by a freeze-casting process, is used as the anode current collector of the lithium battery. The porous metal foam can be heat-treated to form an active oxide material to form on the surface of the metal foam. The oxide material acts as the three-dimensional active material that reacts with lithium ions during charging and discharging.

A process for high integrity castings of metals and their alloys includes the steps of providing at least a sand mold at desired elevated temperatures, delivering a molten metal into the mold, and supplying a predetermined amount of coolant to contact the surfaces of the casting at desired rates, times, and durations to achieve an acceptable level of progressive solidification from the distal end of the casting towards the riser until the casting has reached desired temperatures.