The present invention relates to a casting core for casting molds, wherein the casting core contains or consists of ceramic particles bound with a silica sol. The casting core has a pore structure, in which the average pore size of the pores increases at least in sections from the outside to the inside in the casting core. The present invention also relates to a method for producing the casting core according to the invention and to the use of the casting core according to the invention.

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.

A method of manufacturing a cold box core includes injecting unbonded sand into a cold box core tool, the unbonded sand including sand mixed with a resin, the cold box core tool including: a first platen; a first insert half secured to the first platen; a second platen; and a second insert half secured to the second platen and configured to alternately mate with and separate from the first insert half, each of the first insert half and the second insert half being three-dimensionally printed from a polymer material, the first insert half and the second insert half together forming a cavity therebetween defining an outer geometric shape of the cold box core; and injecting gas into the unbonded sand to harden the cold box core.

A system and method for flexibly forming a casting mold and for manufacturing a casting model or a molded body having a mounting platform, a plurality of shaping rods for forming the casting mold or the molded body and a conveying unit for conveying the shaping rods to the mounting platform, the conveying unit is configured to individually grip and to place the shaping rods on the mounting platform, such that a stack of the shaping rods is formable, and that a side of the stack is formable by the position of the shaping rods, to form a region of the casting mold and wherein the positions of the single shaping rods in the stack reproduce the shape of the molded body, wherein the shaping rods are gluable to each other, such that the stack forms the molded body.

A system and method for flexibly forming a casting mold and for manufacturing a casting model or a molded body having a mounting platform, a plurality of shaping rods for forming the casting mold or the molded body and a conveying unit for conveying the shaping rods to the mounting platform, the conveying unit is configured to individually grip and to place the shaping rods on the mounting platform, such that a stack of the shaping rods is formable, and that a side of the stack is formable by the position of the shaping rods, to form a region of the casting mold and wherein the positions of the single shaping rods in the stack reproduce the shape of the molded body, wherein the shaping rods are gluable to each other, such that the stack forms the molded body.

Provided are: a mold material having improved fluidity and being capable of improving a filling rate of a forming mold during formation of a casting mold; and a mold material that gives cast products a favorable casting surface, effectively improves sand adhesion on cast products, and advantageously provides a casting mold having excellent strength. The mold material is formed as a coated sand in a wet state with spherical particles of silicone resin having binder repellency existing on its surface, by at least mixing a water-soluble inorganic binder in the liquid state having a viscosity of not more than 1000 cP, and the spherical particles of silicone resin, with a refractory aggregate.

The present invention relates to a coating composition, comprising a solids component which comprises a first solid that is able to cleave CO2 in a temperature range from about 150 to about 1000° C., and that has a D50 value of at most about 10 pm. It is furthermore directed to a method for coating a casting mold, the use of the coating composition for coating a casting mold, and the coated casting mold.

A leachable casting core and method of manufacture may include a plurality of legs configured to establish a plurality of internal flow channels of a cast component. Tie bars, with a first tie bar end and a second tie bar end opposite thereof, may couple to at least two of the plurality of legs. At least one of the tie bars may be oriented to form a linking cavity within the cast component between the internal flow channels. The linking cavity may serve as an obstruction to fluid communication through the linking cavity.

A leachable casting core and method of manufacture may include a plurality of legs configured to establish a plurality of internal flow channels of a cast component. Tie bars, with a first tie bar end and a second tie bar end opposite thereof, may couple to at least two of the plurality of legs. At least one of the tie bars may be oriented to form a linking cavity within the cast component between the internal flow channels. The linking cavity may serve as an obstruction to fluid communication through the linking cavity.