A method of manufacturing a component (124) having a main body (116) and at least one ring sleeve (118) through a molding assembly (100), the method comprising: providing a mold (102) having an inlet (115) and defining a hollow portion (H); placing at least one core to form a free-space (104, 106) within the component (124) inside the mold (102) to bifurcate the hollow portion (H) into a first cavity and a second cavity; pouring a molding material (117) inside the mold (102) through the inlet (115); allowing the molding material (117) to set inside the mold (102) around the core within the first cavity and the second cavity to form a main body (116) and at least one ring sleeve (118) of the component (124); connecting the first cavity and the second cavity and forming at least one first bond and one second bond (130, 132, 134, 136) between the main body (116) and the at least one ring sleeve (118); and removing the at least one core from at least part of the hollow portion (H) within the mold (102); characterized in that: providing the core with at least one recess allowing the molding material (117) to flow therethrough such that on withdrawing the core out of the mold (102), at least one first bond (130, 132) breaks and on withdrawing the core outside the mold (102), at least one second bond (134, 136) breaks.

A component formed of metal, such as aluminum, and including a hollow core is provided. The component can be used as a cradle, rail, A-pillar, twist axle, control arm, or shock tower, for example. The component is manufactured by a high pressure vacuum die casting (HPVDC) process. To form the component with the hollow core, a blown or stamped hollow glass core is placed in a die cavity of the high pressure vacuum die casting apparatus, and the metal is melted and injected into the die cavity around the glass core. The metal is then cast and solidifies around the glass core. After the casting process, the glass core can be shattered, removed from the cast component, and recycled.

An engine block assembly and method manufacturing an engine block assembly and related components. A casted engine block assembly includes a cylinder block portion. The cylinder block portion includes a plurality of cylinder block openings disposed therein, a cylinder block flange portion positioned at a top of the cylinder block portion and a cylinder block crankcase portion disposed at a base of the cylinder block. The cylinder block flange portion is configured for coupling the cylinder block to a cylinder head. The cylinder block portion includes a plurality of cylinder block walls extending between the cylinder block flange portion and the cylinder block crankcase portion and positioned about the plurality of cylinder block openings. The cylinder block walls house a plurality of internal channels. The plurality of cylinder block walls are void of enclosed openings extending through at least one of the cylinder block walls in the plurality of cylinder block walls.

A method of manufacturing a replacement body for a component is provided. The method includes the steps of: a) additively manufacturing a crucible for casting of the replacement body; b) solidifying a metal material within the crucible to form a directionally solidified microstructure within the replacement body; and c) removing the crucible to reveal the directionally solidified replacement body.

A method of forming an engine component according to an exemplary aspect of the present disclosure includes, among other things, introducing molten metal into a cavity between a shell and a casting article in the shell. The casting article includes a ceramic portion and a plurality of fibers. The method further includes separately removing the ceramic portion and the fibers from an interior of the component.

A method of forming a component having an internal passage defined therein includes forming a precursor core having a shape corresponding to a shape of the internal passage, and forming a hollow structure around the precursor core. The method also includes removing the precursor core from within the hollow structure, and disposing an inner core within the hollow structure to form a jacketed core. The method further includes positioning the jacketed core with respect to a mold, and introducing a component material in a molten state into a cavity of the mold, such that the component material in the molten state at least partially absorbs the hollow structure from a portion of the jacketed core within the cavity. Additionally, the method includes cooling the component material in the cavity to form the component. The inner core defines the internal passage within the component.

A method of forming a component having an internal passage defined therein includes positioning a jacketed core with respect to a mold. The jacketed core includes a hollow structure formed from a first material, and an inner core formed from an inner core material disposed within the hollow structure. The method also includes introducing a component material in a molten state into a cavity of the mold, such that the component material in the molten state at least partially absorbs the first material from a portion of the jacketed core within the cavity. The method further includes cooling the component material in the cavity to form the component, and removing the inner core material from the component to form the internal passage.

A method of manufacturing a component (124) having a main body (116) and at least one ring sleeve (118) through a molding assembly (100), the method comprising: providing a mold (102) having an inlet (115) and defining a hollow portion (H); placing at least one core to form a free-space (104, 106) within the component (124) inside the mold (102) to bifurcate the hollow portion (H) into a first cavity and a second cavity; pouring a molding material (117) inside the mold (102) through the inlet (115); allowing the molding material (117) to set inside the mold (102) around the core within the first cavity and the second cavity to form a main body (116) and at least one ring sleeve (118) of the component (124); connecting the first cavity and the second cavity and forming at least one first bond and one second bond (130, 132, 134, 136) between the main body (116) and the at least one ring sleeve (118); and removing the at least one core from at least part of the hollow portion (H) within the mold (102); characterized in that: providing the core with at least one recess allowing the molding material (117) to flow therethrough such that on withdrawing the core out of the mold (102), at least one first bond (130, 132) breaks and on withdrawing the core outside the mold (102), at least one second bond (134, 136) breaks.

A pair of main molds forming an outer peripheral face of a piston and a pair of side cores forming the pair of cutout recess parts of the piston are prepared, the main mold and the side core are set so as to form a cavity corresponding to the piston, the cavity is charged with molten metal, and when the side core is moved downward and in a direction away from the central axis of the piston so as to carry out mold release from the cutout recess part after the piston within the cavity has solidified, the side core is tilted in a direction in which an upper end thereof approaches the central axis of the piston. Thus, it is possible to release a core smoothly from a cutout recess part without it biting into an inside face of the cutout recess part.

A method of manufacturing a replacement body for a component is provided. The method includes the steps of: a) additively manufacturing a crucible for casting of the replacement body; b) solidifying a metal material within the crucible to form a directionally solidified microstructure within the replacement body; and c) removing the crucible to reveal the directionally solidified replacement body.