A coupler having a support provided through the body of the coupler and a plurality of openings in the coupler which are configured as open cavities. The coupler structure includes a shank that has a vertical support as well as lateral support. The coupler may be configured with a double I-beam structure with openings into the shank. Cores that may be fixed to the mold may be used to form the coupler and produce the openings in the shank.

A casting method is provided that includes a mold, a mixer, and first and second materials. A first pour and a second pour are dispensed from the mixer. The first pour has different proportions of the first and second materials as compared to the second pour. The first pour forms a first layer of a molded part, and the second pour forms a second layer of the molded part.

In a casting device, positions of discharge ends discharging cooling gas, of respective gas supply nozzles are adjusted in response to movement of a mold. This makes it possible to stably achieve high cooling performance for the mold by blowing of the cooling gas. To adjust the positions of the respective discharge ends, the gas supply nozzles are advanced or retreated, or are expanded or contracted. Further, a cooling chamber may include a radiation cooling portion that cools the mold by radiation, and the radiation cooling portion is disposed below the gas supply nozzles that are provided directly below a heat shielding body partitioning a heating chamber and the cooling chamber.

In a casting device, positions of discharge ends discharging cooling gas, of respective gas supply nozzles are adjusted in response to movement of a mold. This makes it possible to stably achieve high cooling performance for the mold by blowing of the cooling gas. To adjust the positions of the respective discharge ends, the gas supply nozzles are advanced or retreated, or are expanded or contracted. Further, a cooling chamber may include a radiation cooling portion that cools the mold by radiation, and the radiation cooling portion is disposed below the gas supply nozzles that are provided directly below a heat shielding body partitioning a heating chamber and the cooling chamber.

An investment casting core system includes first and second investment casting cores. The first investment casting core has a pin and the second investment casting core has a hole and an access slot that opens to the hole. The pin is disposed in the hole such as to space the first investment casting core in a fixed position relative to the second investment casting core. A bonding agent is disposed in the access slot and around the pin in the hole.

A core pattern reformer system for adjusting and setting a core pattern for use in casting a gas turbine blade has a first portion having a first internal face with a concave portion. The first portion is coupled to a second portion. The second portion has a second internal face with a convex portion. A plurality of adjustable pins is positioned along the internal faces of the first portion and the second portion. The pins have a height that is adjustable with respect to the internal faces. A locking mechanism is included for securing the first portion to the second portion. The system includes one or more air inlets and one or more air exits and a source of cooling air coupled to the one or more air inlets.

A core pattern reformer system for adjusting and setting a core pattern for use in casting a gas turbine blade has a first portion having a first internal face with a concave portion. The first portion is coupled to a second portion. The second portion has a second internal face with a convex portion. A plurality of adjustable pins is positioned along the internal faces of the first portion and the second portion. The pins have a height that is adjustable with respect to the internal faces. A locking mechanism is included for securing the first portion to the second portion. The system includes one or more air inlets and one or more air exits and a source of cooling air coupled to the one or more air inlets.

A method for manufacturing a turbine engine vane a root connected to a blade extending in a longitudinal direction includes the steps of providing a root; and providing mold with a first cavity and a second cavity that together define a recess in which the vane is formed. The recess includes a first space in which the blade is formed and a second space in which the root (1), c) is formed. The method further includes the steps of providing aluminum strips; positioning a fibrous reinforcement; arranging the vane root in the second space; and injecting a foam comprising aluminum or injecting an aluminum alloy into the first space of the recess of the mold such that the foam impregnates the fibrous reinforcement.

A method for manufacturing a blade for a turbine engine, including a root connected to a vane extending in a longitudinal direction, includes providing an assembly having a first part intended to form a root of the blade and a projecting second part projecting in the longitudinal direction from the first part; providing a mold comprising a first impression and a second impression delimiting together a cavity, said cavity comprising a first space and a second space; arranging the first part in the first space of the cavity and the second part in the second space of the cavity; and forming a third part by injecting an aluminium-based alloy in the cavity.

A casting device having a casting mold and a core for producing a helical casting is described. The may have an expendable core that can be dissolved after the casting process. Advantageous effects of the device and process can be achieved by virtue of the fact that the female mold for accommodating the helical casting during the casting process is formed completely within the outer contour of the core, the female mold being delimited by the core and, at the peripheral boundary surfaces of the female mold, by the casting mold.