A core forming method is provided for forming a core. The core forming method includes forming one or more mold parts of water-soluble polymer (WSP), each mold part including a bond area and a part forming area, moistening the bond areas, bonding the mold parts together with the bond areas moistened and the part forming areas aligned to form a cavity shaped as a negative of the core, injecting a slurry, which is non-reactive with the WSP, into the cavity and removing the WSP with water once the slurry is cured.

A method of manufacturing a hollow product using a draft angle is disclosed. A method of manufacturing a hollow product using a draft angle refers to a method of manufacturing a hollow product using a core having a draft angle. The core is formed to protrude in one direction and has an outer surface at a perimeter of a protruding portion of the core, the outer surface of the core forms a slope with respect to the one direction, and a cross-sectional area of the core decreases as the core goes toward a protruding direction. The method comprises disposing a mold to be spaced apart from the outer surface of the core, disposing a hollow tube between the core and the mold, injecting a molten metal into a space between the core and the mold, and removing the core when the molten metal is solidified and the hollow product is molded.

A method of manufacturing a hollow product using a draft angle is disclosed. A method of manufacturing a hollow product using a draft angle refers to a method of manufacturing a hollow product using a core having a draft angle. The core is formed to protrude in one direction and has an outer surface at a perimeter of a protruding portion of the core, the outer surface of the core forms a slope with respect to the one direction, and a cross-sectional area of the core decreases as the core goes toward a protruding direction. The method comprises disposing a mold to be spaced apart from the outer surface of the core, disposing a hollow tube between the core and the mold, injecting a molten metal into a space between the core and the mold, and removing the core when the molten metal is solidified and the hollow product is molded.

Airfoils bodies having a first core cavity and a second core cavity located within the airfoil body that is adjacent the first core cavity. The second core cavity is defined by a first cavity wall, a second cavity wall, a first exterior wall, and a second exterior wall, wherein the first cavity wall is located between the second core cavity and the first core cavity and the first and second exterior walls are exterior walls of the airfoil body. The first cavity wall includes a first surface angled toward the first exterior wall and a second surface angled toward the second exterior wall. At least one first cavity impingement hole is formed within the first surface and a central ridge extends into the second core cavity from at least one of the first cavity wall and the second wall and divides the second core cavity into a two-vortex chamber.

Airfoils bodies having a first core cavity and a second core cavity located within the airfoil body that is adjacent the first core cavity. The second core cavity is defined by a first cavity wall, a second cavity wall, a first exterior wall, and a second exterior wall, wherein the first cavity wall is located between the second core cavity and the first core cavity and the first and second exterior walls are exterior walls of the airfoil body. The first cavity wall includes a first surface angled toward the first exterior wall and a second surface angled toward the second exterior wall. At least one first cavity impingement hole is formed within the first surface and a central ridge extends into the second core cavity from at least one of the first cavity wall and the second wall and divides the second core cavity into a two-vortex chamber.

A casting core assembly is disclosed herein. The casting core assembly comprises a casting core and a bumper assembly. The bumper assembly is disposed on an outer surface of the casting core. The bumper assembly comprises a receptacle and a metal apparatus. The metal apparatus may be a pin, a sphere, or the like.

A casting core assembly is disclosed herein. The casting core assembly comprises a casting core and a bumper assembly. The bumper assembly is disposed on an outer surface of the casting core. The bumper assembly comprises a receptacle and a metal apparatus. The metal apparatus may be a pin, a sphere, or the like.

A hybrid casting process for structural components uses a re-usable metallic mold rather than a sand mold to produce more consistent cast components. The hybrid casting process uses a metallic mold coupled to a core mold to produce the near net shape of the cast component. Machining operations are performed on the near net shape cast component to produce a final component that meets tolerances and other specifications of the structural component.

A hybrid casting process for structural components uses a re-usable metallic mold rather than a sand mold to produce more consistent cast components. The hybrid casting process uses a metallic mold coupled to a core mold to produce the near net shape of the cast component. Machining operations are performed on the near net shape cast component to produce a final component that meets tolerances and other specifications of the structural component.

A method of forming a thermally isolated exhaust port, the method comprising applying an endothermic material to an exhaust port core in a mold for an engine cylinder head, forming the engine cylinder head with an exhaust port using a casting process, generating, in the cylinder head with the exhaust port during the casting process, nodular graphite iron proximate the endothermic material around the exhaust port core, and forming the thermally isolated exhaust port containing nodular graphite iron in the cylinder head.