A solution is provided 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.

Partial integrated core-shell investment casting molds that can be assembled into complete molds are provided herein. Each section of the partial mold may contain both a portion of a core and portion of a shell. Each section can then be assembled into a mold for casting of a metal part. The partial integrated core-shell investment casting molds and the complete molds may be provided with filament structures corresponding to cooling hole patterns on the surface of the turbine blade or the stator vane, which provides a leaching pathway for the core portion after metal casting. Core filaments that can be used to supplement the leaching pathway, for example in a core tip portion of the mold are also provided herein.

Partial integrated core-shell investment casting molds that can be assembled into complete molds are provided herein. Each section of the partial mold may contain both a portion of a core and portion of a shell. Each section can then be assembled into a mold for casting of a metal part. The partial integrated core-shell investment casting molds and the complete molds may be provided with filament structures corresponding to cooling hole patterns on the surface of the turbine blade or the stator vane, which provides a leaching pathway for the core portion after metal casting. Core filaments that can be used to supplement the leaching pathway, for example in a core tip portion of the mold are also provided herein.

Device and method for injection moulding a metal alloy intended for manufacturing at least one part made of an amorphous metal alloy or metallic glass, wherein: an injection mould (2) delimits a cavity that has a receiving face (4) and a frontal moulding face (5) opposite the receiving face, at least one sacrificial shaping insert (7) is placed in said cavity and has a rear face (8), at least one contact zone of which is adjacent to at least one contact zone of said receiving face of the cavity and a front face (9) that is situated opposite said moulding face of the mould and provided with a recessed shape, and an injection piston (I I) is movable in a chamber (12) of the mould and communicates with the moulding impression.

A furnace for removing a molybdenum-alloy refractory metal core through sublimation comprising a retort furnace having an interior; a sublimation fixture insertable within the interior of the retort furnace, the sublimation fixture configured to receive at least one turbine blade having the molybdenum-alloy refractory metal core; a flow passage thermally coupled to the retort furnace configured to heat a fluid flowing through the flow passage and deliver the fluid to the molybdenum-alloy refractory metal core causing sublimation of the molybdenum-alloy refractory metal core.

A ceramic resin is provided, along with its methods of formation and use. The ceramic resin may include a crosslinkable precursor, a photoinitiator, ceramic particles, and pore forming particles. The ceramic resin may be utilized to form a ceramic casting element, such as via a method that includes forming a layer of the ceramic resin; applying light onto the ceramic resin such that the photoinitiator initiates polymerization of the crosslinkable precursor to form a crosslinked polymeric matrix setting the ceramic particles and the pore forming particles; and thereafter, heating the crosslinked polymeric matrix to a first temperature to burn out the pore forming particles.

A method of making a test coupon using a mold is provided. The mold defines a mold cavity that comprises a first-grip-portion cavity, a second-grip-portion cavity, an intermediate-portion cavity, interconnecting the first-grip-portion cavity and the second-grip-portion cavity, and runner cavities, directly interconnecting the first-grip-portion cavity and the second-grip-portion cavity and not directly connected to the intermediate-portion cavity. The method comprises injecting feedstock material, comprising a metal powder, into the mold cavity to form a monolithic precursor test coupon in the mold cavity, wherein the monolithic precursor test coupon comprises a first grip portion, a second grip portion, an intermediate portion, and runners. The method also comprises removing the runners from the monolithic precursor test coupon.

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

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.