A mould assembly for producing a casting core for a cooling jacket of an electric motor has an external mould and an internal mould enclosed by the external mould. The external mould forms an outer wall and the internal mould an inner wall of the core moulding cavity fillable with a core material and having a cylindrical shape. The internal mould has two first mould shells and two second mould shells. The two first mould shells and the two second mould shells jointly form the inner wall of the core moulding cavity. The second mould shells are arranged between the first mould shells. A first demoulding mechanism is arranged between the first mould shells and enables movement of the first mould shells toward one another. A second demoulding mechanism is arranged between the second mould shells and enables movement of the second mould shells toward one another.

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 integrated core-shell investment casting molds that provide an indentation structure corresponding to a thin root component of the turbine blade or vane (i.e. angel wing, skirt, damper lug).

The present disclosure generally relates to integrated core-shell investment casting molds that provide filament structures corresponding to cooling hole patterns on the surface of the turbine blade or stator vane, which 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 as or stator vane, which 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 invention provides a method of forming a leading edge for an aerofoil component e.g. an aerofoil blade. The method comprises forming a pre-form having a precursor edge and processing said precursor edge to form the leading edge. The pre-form is formed using metal injection molding. The leading edge may have an elliptical profile.

An embodiment core molding system includes an upper hopper partitioned to define a first accommodating part that accommodates first core sand coated with an organic binder and a second accommodating part that accommodates pure sand, a lower hopper disposed under the upper hopper and connected to the first and second accommodating parts, the lower hopper being configured to measure weights of the first core sand and the pure sand, a mixer connected to the lower hopper, wherein the mixer is configured to allow the first core sand to pass directly therethrough and to accommodate the pure sand, a binder supply unit connected to the mixer and configured to supply an inorganic binder into the mixer, and a core mold configured to mold each of the first core sand and second core sand into a preset shape, the second core sand including the pure sand coated with the inorganic binder.

An embodiment core molding system includes an upper hopper partitioned to define a first accommodating part that accommodates first core sand coated with an organic binder and a second accommodating part that accommodates pure sand, a lower hopper disposed under the upper hopper and connected to the first and second accommodating parts, the lower hopper being configured to measure weights of the first core sand and the pure sand, a mixer connected to the lower hopper, wherein the mixer is configured to allow the first core sand to pass directly therethrough and to accommodate the pure sand, a binder supply unit connected to the mixer and configured to supply an inorganic binder into the mixer, and a core mold configured to mold each of the first core sand and second core sand into a preset shape, the second core sand including the pure sand coated with the inorganic binder.

A sand core making machine that includes a hopper having a hollow body with an inner surface delimiting a passageway for a material used in the manufacture of a sand core. The hopper includes a plurality of breaker assemblies with each breaker assembly having at least one string. The ends of a string are attached to corresponding attachment points of the inner surface of the hollow body, such that the strings are arranged in a flow passage of the material. At least two breaker assemblies are spaced apart such that the two breaker assemblies interact with each other to break lumps of the material supplied to the hopper when the hollow body is shaken.

A setter for an investment casting core is provided. The setter may include: a base section; and a cover section configured to mechanically couple to the base section and having a profile for receiving the investment casting thereon. A setter array for a plurality of investment casting cores is further provided. A method for supporting an investment casting core during heat treatment using the setter is also provided.