Sand for a casting mold including sand, a binder, and an inorganic compound particle having poor water solubility and generating a gas, which is at least one of water vapor or carbon dioxide gas, by heat from a molten metal.

A method of catching overflow of a liquid fluid utilized to cast a component is disclosed. Sand is compacted to form a mold. A cutter of a cutting device is in a disengaged position spaced from a top surface of the mold when the cutting device is in a first position and the cutter is in an engaged position engaging the top surface of the mold when the cutting device is in a second position. The cutter is actuated when the cutting device is in the second position and the cutter is in the engaged position to remove sand from the top surface to define a recess therein to catch overflow of the liquid fluid. The recess is spaced from an opening. At least one blocking mechanism, blowing mechanism and adjustment mechanism is utilized to assist the cutting device.

A method of catching overflow of a liquid fluid utilized to cast a component is disclosed. Sand is compacted to form a mold. A cutter of a cutting device is in a disengaged position spaced from a top surface of the mold when the cutting device is in a first position and the cutter is in an engaged position engaging the top surface of the mold when the cutting device is in a second position. The cutter is actuated when the cutting device is in the second position and the cutter is in the engaged position to remove sand from the top surface to define a recess therein to catch overflow of the liquid fluid. The recess is spaced from an opening. At least one blocking mechanism, blowing mechanism and adjustment mechanism is utilized to assist the cutting device.

A cast component includes a cast structure having a primary geometry formed by a mold. Also included is a structural deposit formed by cold spraying one or more layers of powdered material on an outer surface of the cast structure, the structural deposit defining at least one feature of the overall outer geometry of the cast component in addition to the primary geometry. Also provided are methods of manufacturing the cast component.

A cast component includes a cast structure having a primary geometry formed by a mold. Also included is a structural deposit formed by cold spraying one or more layers of powdered material on an outer surface of the cast structure, the structural deposit defining at least one feature of the overall outer geometry of the cast component in addition to the primary geometry. Also provided are methods of manufacturing the cast component.

A process for the casting of metals and their alloys includes the steps of providing at least a mold equipped with a plurality of cooling nozzles, making a layer of coolant permeable materials covering the nozzles and maintaining the materials at desired temperatures, delivering a molten metal into the mold, supplying predetermined amount of coolant to each nozzles to contact the casting at desired rate, time, and duration 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.

The present disclosure generally relates to casting molds including a casting core comprising a first metal component and a second metal component. In an aspect, the first metal component has a lower melting point than the second metal component. In another aspect, the second metal component surrounds at least a portion of the first metal component and defines a cavity in the casting core when the first metal component is removed and the second metal component is not removed.

The present disclosure generally relates to casting molds including a casting core comprising a first metal component and a second metal component. In an aspect, the first metal component has a lower melting point than the second metal component. In another aspect, the second metal component surrounds at least a portion of the first metal component and defines a cavity in the casting core when the first metal component is removed and the second metal component is not removed.

The binder coated refractories comprises the refractory aggregates and the solid-form coating layer which comprises the sugar group as the binder and which is provided to the surface of the refractory aggregates. According to this, the sugar group is used as the binder for bonding the refractory aggregates. Further, even if the sugar group is thermally decomposed, the sugar group emits the carbon dioxide and the water. Therefore, there is little likelihood of emitting the harmful gas. Therefore, it is possible to reduce the environmental pollution. Further, the sugar group is thermally decomposed easily. Therefore, it is possible to manufacture the casting mold having the good breaking property.

The binder coated refractories comprises the refractory aggregates and the solid-form coating layer which comprises the sugar group as the binder and which is provided to the surface of the refractory aggregates. According to this, the sugar group is used as the binder for bonding the refractory aggregates. Further, even if the sugar group is thermally decomposed, the sugar group emits the carbon dioxide and the water. Therefore, there is little likelihood of emitting the harmful gas. Therefore, it is possible to reduce the environmental pollution. Further, the sugar group is thermally decomposed easily. Therefore, it is possible to manufacture the casting mold having the good breaking property.