A system and methods are provided for removing core elements of cast components. In one embodiment, a method includes controlling a first high temperature autoclave cycle for a cast component in a vessel with a first solution concentration to remove at least a first portion of core elements, wherein the first solution concentration, temperature and pressure in the vessel are controlled to expose one or more casting pins in the cast component. The method may also include controlling a second high temperature autoclave cycle for the cast component in the vessel with second solution concentration, wherein the second solution concentration, temperature and pressure in the vessel during the second high temperature autoclave cycle are controlled to loosen one or more of the casting pins from the cast component, and controlling one or more low temperature autoclave cycles to remove core and casting pins from the cast component.

A system and methods are provided for removing core elements of cast components. In one embodiment, a method includes controlling a first high temperature autoclave cycle for a cast component in a vessel with a first solution concentration to remove at least a first portion of core elements, wherein the first solution concentration, temperature and pressure in the vessel are controlled to expose one or more casting pins in the cast component. The method may also include controlling a second high temperature autoclave cycle for the cast component in the vessel with second solution concentration, wherein the second solution concentration, temperature and pressure in the vessel during the second high temperature autoclave cycle are controlled to loosen one or more of the casting pins from the cast component, and controlling one or more low temperature autoclave cycles to remove core and casting pins from the cast component.

A method of manufacturing a crankshaft assembly includes configuring a crankshaft with a crankpin journal having a cavity extending at least partially from a first axial side to a second axial side of the crankpin journal, and opening at at least one of the first axial side and the second axial side. The method includes disposing a core plug in the cavity. The crankshaft has a first density and the core plug may have a second density which may be less than the first density. A crankshaft assembly includes the crankshaft and the core plug.

A brake caliper adapted for use in a vehicle disc brake assembly and method and apparatus for producing the same. The apparatus for producing the brake caliper comprises a mold member and a core member. The mold member has two mold sections meeting at a vertical interface, the first mold section having an extension from the vertical interface into the second mold section to form an integrally cast lug on the brake caliper. The core member has three extensions operative to form three integrally cast locating surfaces on the cast brake caliper, the extensions defining datum surfaces for subsequent machining of the cast brake caliper to predetermined tolerances using the three locating surfaces as the datum surfaces.

A method to manufacture reticulated metal foam via a dual investment, includes pre-investment of a precursor with a diluted pre-investment ceramic plaster then applying an outer mold to the encapsulated precursor as a shell-mold.

A die cast system in which an external shell and an internal core usable to form a component of a gas turbine engine are formed together is disclosed. In at least one embodiment, the external shell and internal core may be formed from at the same time via a selective laser melting process, thus eliminating the need for using the conventional lost-wax casting system. In at least one embodiment, the external shell and internal core may be formed a ceramic material that may support receiving molten metal to form a turbine component. Once formed, the external shell and internal core may be removed to reveal the turbine component.

A foundry method of casting monocrystalline metal parts, the method including at least casting a molten alloy into a cavity of a mold through at least one casting channel in the mold, subjecting the alloy to heat treatment, and removing the mold, and wherein the heat treatment is performed before an end of mold removal.

A foundry method of casting monocrystalline metal parts, the method including at least casting a molten alloy into a cavity of a mold through at least one casting channel in the mold, subjecting the alloy to heat treatment, and removing the mold, and wherein the heat treatment is performed before an end of mold removal.

A solution is provided and includes a strong base, a corrosion inhibitor, wherein the strong base is an alkali metal hydroxide, wherein the corrosion inhibitor is at least one of an organic acid having a-COOH functional group or an alkali metal salt of one of an organic acid having a-COOH functional group.

To obtain an impact wave by generation of arc discharge between a high-voltage-side electrode 31 connected to a high-voltage-side terminal of a pulse power generating device and a low-voltage-side electrode 32 grounded or connected to a low-voltage-side terminal of the power source. One of the high-voltage-side electrode 31 or the low-voltage-side electrode 32 is an annular electrode formed in an annular shape, the other electrode is a core electrode arranged inside the annular electrode, and arc discharge is generated between an inner peripheral portion of the annular electrode and an outer peripheral portion of the core electrode.