A method for casting an article comprises a first region and a second region. The method comprises casting an alloy in a shell, the shell having a casting core protruding from a first metal piece; and deshelling and decoring to remove the shell and core and leave the first region formed by the first piece and the second region formed by the casted alloy.

A counter gravity casting apparatus includes a reusable metal mold having a plurality of mold cavities, a feed tube configured to feed molten alloy into the mold, and a vacuum fitting configured to permit a vacuum to be applied to the mold. The mold includes multiple metal sections configured such that adjacent metal sections mate to one another, the metal sections being separable from one another. The metal sections include recesses that form the mold cavities, and the mold includes a sprue and multiple runner passages. The sprue is configured to receive molten alloy from the feed tube, and the multiple runner passages are configured to feed molten alloy from the sprue to the mold cavities. Methods of casting bulk amorphous alloy articles or feedstock is described.

Methods are provided for manufacturing a component. In one method, first material is cast into a first body. At least a portion of the first body is machined. Second metal material is cast onto at least the machined portion of the first body to form a monolithic second body. A first portion of the second body is formed by the first metal material. A second portion of the second body is formed by the second metal material. The second metal material is different from the first metal material.

A method is provided for manufacturing a component. This method includes additively manufacturing a crucible for casting of the component. A metal material is directionally solidified within the crucible to form a metal single crystal material. A sacrificial core is removed to reveal a metal single crystal component with internal passageways. A component is provided for a gas turbine engine that includes a metal single crystal material component with internal passageways. The metal single crystal material component was additively manufactured of a metal material concurrently with a core that forms the internal passageways. The metal material was also remelted and directionally solidified.

Ferritic stainless steel having a high degree of ductility and a method for manufacturing the ferritic stainless steel are provided. The stainless steel includes, by wt %, C: 0.005% to 0.1%, Si: 0.01% to 2.0%, Mn: 0.01% to 1.5%, P: 0.05% or less, S: 0.005% or less, Cr: 10% to 30%, Ti: 0.005% to 0.5%, Al: 0.01% to 0.15%, N: 0.005% to 0.03%, and the balance of Fe and inevitable impurities, wherein the ferritic stainless steel includes 3.5×10.sup.6 or fewer particles of an independent Ti(CN) precipitate per square millimeter (mm.sup.2) of ferrite matrix.

Ferritic stainless steel having a high degree of ductility and a method for manufacturing the ferritic stainless steel are provided. The stainless steel includes, by wt %, C: 0.005% to 0.1%, Si: 0.01% to 2.0%, Mn: 0.01% to 1.5%, P: 0.05% or less, S: 0.005% or less, Cr: 10% to 30%, Ti: 0.005% to 0.5%, Al: 0.01% to 0.15%, N: 0.005% to 0.03%, and the balance of Fe and inevitable impurities, wherein the ferritic stainless steel includes 3.5×10.sup.6 or fewer particles of an independent Ti(CN) precipitate per square millimeter (mm.sup.2) of ferrite matrix.

A directional solidification casting assembly includes a directional solidification mold having an interior chamber with a shape of an object to be cast using directional solidification of molten metal in a growth direction of the mold and a feed line conduit. The conduit is fluidly coupled with a container source of the molten metal and is coupled with the mold at a gating. The feed line conduit conveys the molten metal into the mold through the gating for directional solidification of the object to be cast in the mold. At least a downstream portion of the feed line conduit that is between the intermediate location of the feed line conduit and the second open end of the feed line conduit is located below the gating along the growth direction of the mold.

The present invention provides a method for casting a slab having a good cast surface. The method includes heating the surface of molten metal on a metal inlet side of a mold by a first heat source so that the following formulas: q≧0.87 and c≦11.762q+0.3095 are satisfied where c is a cycle time [sec] of turning movement of the first heat source, and q is an average amount of heat input [MW/m.sup.2] determined by accumulating an amount of heat input applied by at least the first heat source to the contact region between the upper surface of the slab on the metal inlet side and the mold, along the path of turning movement of the first heat source, and dividing the resultant accumulated value by the cycle time c.

A foundry method of casting monocrystalline metal parts, the method including at least casting a molten alloy into a cavity of a mold through at least one casting channel in the mold, subjecting the alloy to heat treatment, and removing the mold, and wherein the heat treatment is performed before an end of mold removal.

A foundry method of casting monocrystalline metal parts, the method including at least casting a molten alloy into a cavity of a mold through at least one casting channel in the mold, subjecting the alloy to heat treatment, and removing the mold, and wherein the heat treatment is performed before an end of mold removal.