A method of bonding a mini-core to a surface of a core is provided. The method includes providing the mini-core with an attachment device that includes a protrusion of a surface of the mini-core, dipping the protrusion into a supply of paste to transfer a fixed quantity of paste to the protrusion and affixing the protrusion to the surface of the core with the fixed amount of paste interposed between the surface and the protrusion.

A method includes casting a metallic material (56) in a mold (20) containing a core, the core having a substrate (40, 44) coated with a coating (42). A removing of the metallic material from the mold and decoring leaves a casting having a layer formed by the coating. The coating has a ceramic having a porosity in a zone (50) near the substrate less than a porosity in a zone (52) away from the substrate.

A method of forming a casting with a flow passage may include forming a core obtained by filling a tubular pipe with a filler; inserting the core into a mold having a cavity corresponding to a shape of the casting to be formed; performing a casting process by injecting molten metal into the cavity; and removing the filler from the core, wherein the casting process is performed through a high-pressure casting process.

In various embodiments, a microreactor features a corrosion-resistant microchannel network encased within a thermally conductive matrix material that may define therewithin one or more hollow heat-exchange conduits.

A method of producing a ceramic core for investment casting is provided. The method includes injecting a slurry into a disposable die. The slurry includes ceramic particles, a binder, and carbon fibers. The method also includes a first heating to eliminate the disposable die, leaving a cured ceramic core comprising the ceramic particles, binder, and carbon fibers.

The present invention relates to a method of manufacturing a cooling device using a heat pipe in which, using casting, the heat pipe is embedded inside a housing, and the method includes a filling step in which a predetermined support member is filled inside a pipe to prevent deformation of the pipe by a pressure of a melt being injected into a cavity of a mold that is closeable, a pipe seating step in which the pipe filled with the predetermined support member is seated in the cavity, a melt injecting step in which the melt is injected into the cavity to surround the pipe, a cooling and withdrawing step in which the injected melt is cooled and a molded product is withdrawn, an injecting step in which a working fluid is injected into the pipe through an injection end, and a finishing step in which, after the injecting step, the pipe is sealed.

The present invention relates to a multicore and a method of manufacturing a hollow product using the multicore enabling a hollow of a molded product to be molded more easily by casting and a quality problem to be addressed, and the multicore includes a first core, being made of a water-insoluble material, having a hollow formed in the first core and, having an opening formed at both ends of the first core so that the hollow is exposed to the outside through the opening, a second core, being made of a water-soluble material and disposed inside the hollow, and a coating layer, being configured to surround the first core to prevent the first core and the second core from being exposed to an outside, wherein the first core includes a plurality of spaces to allow a fluid supplied to an interior of the first core to flow toward the second core.

The present invention relates to a core for hollow product manufacture including a multilayer filling material, which may be used in forming a cooling water circulation channel through which a fluid such as cooling water may pass, and a method of manufacturing a hollow product using the core, and the core includes a pipe, having a hollow formed in the pipe and an opening formed at both ends of the pipe so that the hollow is exposed to the outside through the opening, a first support member, being disposed inside the hollow and having a space formed in the first support member, a second support member, being disposed in the space, and a melting bar, passing through the second support member in a longitudinal direction of the melting bar, wherein the melting bar melts and forms a space in the second support member when the melting bar is heated.

Methods for forming composite components with sealed bi-material interfaces include applying a sacrificial material to a surface of a substrate, over-molding the substrate and the sacrificial material with an over-molding material such that the over-molding material covers at least a portion of the sacrificial material and at least one surface of the substrate, removing the sacrificial material by deflagration to form a composite component with a channel between the substrate and the over-molding material, introducing an uncured sealant into the channel, and curing the sealant to form a sealed composite component. The method can further include removing a portion of the sealant prior to the sealant fully curing. The sealed composite component can include a passage, encircled by the channel, extending between the substrate and the over-molding material. The substrate can be a metal, a polymer, a polymer composite, a ceramic, or a continuous fiber composite material.

A mold assembly for use in forming a component having an outer wall of a predetermined thickness includes a mold and a jacketed core. The jacketed core includes a jacket that includes a first jacket outer wall coupled against an interior wall of the mold, a second jacket outer wall positioned interiorly from the first jacket outer wall, and at least one jacketed cavity defined therebetween. The at least one jacketed cavity is configured to receive a molten component material therein. The jacketed core also includes a core positioned interiorly from the second jacket outer wall. The core includes a perimeter coupled against the second jacket outer wall. The jacket separates the perimeter from the interior wall by the predetermined thickness, such that the outer wall is formable between the perimeter and the interior wall.