A fabrication method for fabricating a pattern for lost pattern casting, comprising at least one insert (10), providing at least two pattern portions (12, 14), said at least two portions being made of a material that can be eliminated, and assembling said at least two pattern portions together around at least a portion of said at least one insert in sealed manner so as to make said pattern (16).

A casting core may include a core body and a tip comb extending from a tip region of the core body. The tip comb may be integrally formed with the core body. The tip comb may comprise a first casting pedestal and a second casting pedestal. The first casting pedestal and the second casting pedestal may define an aperture having a tapered geometry.

The present disclosure generally relates to integrated core-shell investment casting molds that provide filament structures corresponding to cooling hole patterns in the surface of the turbine blade or stator vane, including in locations that are inaccessible due to the presence of protrusion patterns. The filament structures also provide a leaching pathway for the core portion after metal casting. The invention also relates to core filaments that can be used to supplement the leaching pathway, for example in a core tip portion of the mold.

The present disclosure generally relates to partial integrated core-shell investment casting molds that can be assembled into complete molds. 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. The invention also relates to core filaments that can be used to supplement the leaching pathway, for example in a core tip portion of the mold.

The present disclosure generally relates to partial integrated core-shell investment casting molds that can be assembled into complete molds. 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. The invention also relates to core filaments that can be used to supplement the leaching pathway, for example in a core tip portion of the mold.

An example system includes a casting mold and a casting core. The casting core includes a substrate. A plurality of support structures integral with and extending from the substrate define a plurality of channels. Respective support structures of the plurality of support structures define respective contact surfaces distal from the substrate. A sacrificial composition substantially fully fills the plurality of cooling channels and leaves the respective contact surfaces substantially uncovered. An example technique includes filling the sacrificial composition in the plurality of cooling channels, and casting a cover layer onto the respective contact surfaces of the plurality of support structures.

The invention relates to the foundry field, and in particular to a foundry process comprising the preheating of a mold (1) up to a first temperature, the casting of a metal in the liquid state, at a second temperature above the first temperature, in the mold kept in a main furnace (100) at the first temperature since the preheating, the difference between the first temperature and second temperature being no more than 80 C., the cooling and solidification of the metal in the mold (1) kept in the main furnace (100) at a pressure of less than 0.1 Pa at least since the casting, the removal of the mold (1) from the main furnace (100), and the demolding of the solidified metal.

The invention relates to the foundry field, and in particular to a foundry process comprising the preheating of a mold (1) up to a first temperature, the casting of a metal in the liquid state, at a second temperature above the first temperature, in the mold kept in a main furnace (100) at the first temperature since the preheating, the difference between the first temperature and second temperature being no more than 80 C., the cooling and solidification of the metal in the mold (1) kept in the main furnace (100) at a pressure of less than 0.1 Pa at least since the casting, the removal of the mold (1) from the main furnace (100), and the demolding of the solidified metal.

A casting method using combined 3D printed shell mold and the combined shell mold used in the method. The method consists of shell mold making and casting steps. The shell mold is constructed by combination. First, the 3D printer at least prints out a runner part and several pattern die parts for molding products. In the print run, the first interfaces corresponding to the quantity of pattern die parts are printed out integrally on the runner part. The second interfaces corresponding to the first interfaces are formed on the pattern die parts. Afterwards, the first interfaces and the second interfaces are butted, the primary runner in runner part is connected to the die cavities in pattern die parts, the runner part and pattern die parts are combined to form a shell mold for casting multiple products at a time.

A casting method using combined 3D printed shell mold and the combined shell mold used in the method. The method consists of shell mold making and casting steps. The shell mold is constructed by combination. First, the 3D printer at least prints out a runner part and several pattern die parts for molding products. In the print run, the first interfaces corresponding to the quantity of pattern die parts are printed out integrally on the runner part. The second interfaces corresponding to the first interfaces are formed on the pattern die parts. Afterwards, the first interfaces and the second interfaces are butted, the primary runner in runner part is connected to the die cavities in pattern die parts, the runner part and pattern die parts are combined to form a shell mold for casting multiple products at a time.