A method of forming a cast component and a method of forming a casting mold. The method is performed by connecting at least one wax gate component to a ceramic core-shell mold. The ceramic core-shell mold includes at least a filter, first core portion, a first shell portion, and at least one first cavity between the core portion and the first shell portion. The core-shell mold may be manufactured using an additive manufacturing process and may include an integrated ceramic filter. At least a portion of the ceramic core-shell mold and the wax gate component is coated with a second ceramic material. The wax gate component is then removed to form a second cavity in fluid communication with the first cavity.

A method for producing a cast workpiece includes the following method steps: providing a mold having at least one mold core arranged in the mold; inserting a metal melt into the mold; waiting for a period of time until at least the outer contour of the metal melt has solidified and the workpiece has been formed from the metal melt; removing the workpiece from the mold; shattering the mold core, wherein this method step is carried out before the workpiece has entirely cooled down from the casting process. For shattering the mold core, a hammer head is applied on a defined energy transmission surface of the workpiece and the energy transmission surface is acted on, in particular hit on, by the hammer head.

According to some aspects, a method is provided of casting an object from a mold, the method comprising obtaining a mold comprising a hollow shell of rigid material, the material comprising a thermoset polymer having a plurality of pores formed therein, providing a metal and/or ceramic slurry into an interior of the mold, exposing at least part of the mold to a low pressure environment so that a net flow of gas is produced from the interior of the mold into the low pressure environment. According to some aspects, a method of forming a porous mold is provided. According to some aspects, a photocurable liquid composition is provided, comprising a liquid photopolymer resin, particles of a solid material, in an amount between 30% and 60% by volume of the composition, and a water-soluble liquid.

According to some aspects, a method is provided of casting an object from a mold, the method comprising obtaining a mold comprising a hollow shell of rigid material, the material comprising a thermoset polymer having a plurality of pores formed therein, providing a metal and/or ceramic slurry into an interior of the mold, exposing at least part of the mold to a low pressure environment so that a net flow of gas is produced from the interior of the mold into the low pressure environment. According to some aspects, a method of forming a porous mold is provided. According to some aspects, a photocurable liquid composition is provided, comprising a liquid photopolymer resin, particles of a solid material, in an amount between 30% and 60% by volume of the composition, and a water-soluble liquid.

The present invention provides a tube body that is to be used in a high-temperature atmosphere and a method for stably forming a metal oxide layer on an inner surface of the tube body at a high area percentage wherein the tube body is constituted by a heat-resistant alloy containing Cr in an amount of 15 mass % or more and Ni in an amount of 18 mass % or more, so that the inner surface has an arithmetic average roughness (Sa) of three-dimensional surface roughness that satisfies 1.5 μm≤Sa≤5.0 μm and a skewness (Ssk) of a surface height distribution that satisfies |Ssk|≤0.30, wherein the heat-resistant alloy may contain Al in an amount of 2.0 mass % or more and the inner surface may have a kurtosis (Sku) of a surface height distribution of the three-dimensional surface roughness that satisfies Sku≥2.5.

The present invention provides a tube body that is to be used in a high-temperature atmosphere and a method for stably forming a metal oxide layer on an inner surface of the tube body at a high area percentage wherein the tube body is constituted by a heat-resistant alloy containing Cr in an amount of 15 mass % or more and Ni in an amount of 18 mass % or more, so that the inner surface has an arithmetic average roughness (Sa) of three-dimensional surface roughness that satisfies 1.5 μm≤Sa≤5.0 μm and a skewness (Ssk) of a surface height distribution that satisfies |Ssk|≤0.30, wherein the heat-resistant alloy may contain Al in an amount of 2.0 mass % or more and the inner surface may have a kurtosis (Sku) of a surface height distribution of the three-dimensional surface roughness that satisfies Sku≥2.5.

According to some aspects, a method is provided of casting an object from a mold, the method comprising obtaining a mold comprising a hollow shell of rigid material, the material comprising a thermoset polymer having a plurality of pores formed therein, providing a metal and/or ceramic slurry into an interior of the mold, exposing at least part of the mold to a low pressure environment so that a net flow of gas is produced from the interior of the mold into the low pressure environment. According to some aspects, a method of forming a porous mold is provided. According to some aspects, a photocurable liquid composition is provided, comprising a liquid photopolymer resin, particles of a solid material, in an amount between 30% and 60% by volume of the composition, and a water-soluble liquid.

According to some aspects, a method is provided of casting an object from a mold, the method comprising obtaining a mold comprising a hollow shell of rigid material, the material comprising a thermoset polymer having a plurality of pores formed therein, providing a metal and/or ceramic slurry into an interior of the mold, exposing at least part of the mold to a low pressure environment so that a net flow of gas is produced from the interior of the mold into the low pressure environment. According to some aspects, a method of forming a porous mold is provided. According to some aspects, a photocurable liquid composition is provided, comprising a liquid photopolymer resin, particles of a solid material, in an amount between 30% and 60% by volume of the composition, and a water-soluble liquid.

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.