A foundry mixture for making molds used for molding cast metal parts includes foundry sand, a non-aqueous binder, and a cleaning agent that includes calcium oxide. Residual foundry mixture remaining on the cast part after removal from the mold is removed by electrolytic cleaning of the cast part.

A gas turbine engine, a blisk and methods of manufacturing are disclosed. The blisk includes a disk and a plurality of blades. Each blade includes a platform, an airfoil, and a shank portion radially extending between the platform and the disk. The airfoil includes cooling features. Cooling cavities are defined between shank portions of adjacent blades and are in communication to the internal of blades via cooling feed channels. A coverplate is coupled to a downstream side of the blisk to cover the cooling cavities. A plurality of inner tabs extends from an inner edge of the coverplate to securely couple the coverplate to the disk. The disk and the plurality of blades may be integrally formed or casted as a single unit. The platform, the airfoil, and the shank portion may be formed integrally as a single unit and bonded to the disk to form the blisk.

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.

Provided is a molding device for manufacturing a molded product having an arc-shaped bent inner space, wherein the molding device includes: a pair of molds which is joinable to each other and separable from each other, and is capable of forming a cavity C which has a shape corresponding to an outer shape of the molded product in a joined state during molding; a core which has a shape corresponding to an inner shape of the molded product, and is disposed in the inside of the cavity C which the pair of molds forms during molding; and a rotation member which is joined to a terminal end of the core, and is rotatable together with the core after molding. Compared to a conventional molding device, the molding device of the present invention becomes a molding device capable of suppressing the occurrence of a defect on a molded product having an arc-shaped bent inner space at the time of taking out the molded product.

A method for producing an article (1) having a cavity (4), in which method a mould (2) provided with a core (3) is filled with article material, the article material is hardened around the core (3) to form the article (1), and the core (3) is removed from the solidified article (1). The core (3) is made of yttria tetragonal zirconia polycristal material (Y-TZP) or partially stabilized zirconium (PSZ), and after the hardening phase the core (3) is exposed to a steam atmosphere, after which the core (3) is removed from the article (1).

A method of manufacturing a core for casting a component can include manufacturing a core for at least partially forming an internal passage architecture of a component with a material including radiopaque particles. A method can include removing a material including radio opaque particles from an internal passage architecture of a component; and inspecting the component via radiographic imaging at gamma/X-ray wavelengths to detect residual material. A core for use in casting an internal passage architecture of a component can include a material with radiopaque particles dispersed therein.

A casting apparatus includes: a mold including a first mold segment and a second mold segment; and a transfer device that is configured to transfer a core to the first mold segment and place the core in the first mold segment, and to receive and transfer a casting. The transfer device includes a support part, a robot arm, a core grasping mechanism being provided on the support part, and a casting receiving part being provided on the support part. The transfer device is configured such that the robot arm moves the core grasping mechanism so as to place the core in the first mold segment, and moves the casting receiving part so as to receive the casting by the casting receiving part.

A method of forming an airfoil (12), including: abutting end faces (72) of cantilevered film hole protrusions (64) extending from a ceramic core (50) against an inner surface (80) of a wax die (68) to hold the ceramic core in a fixed positional relationship with the wax die; casting an airfoil including a superalloy around the ceramic core; and machining film cooling holes (34) in the airfoil after the casting step to form an pattern of film cooling holes comprising the film cooling holes formed by the machining step and the cast film cooling holes (102) formed by the film hole protrusions during the casting step.

A casting mold assembly includes an airfoil defining section and a casting core. The airfoil defining section includes an outer mold wall and a direct-shelled inner mold wall. The direct-shelled inner mold wall is disposed within a forward chordwise portion of the airfoil defining section. The direct-shelled inner mold wall includes an aft end having an external radius measuring more than about 0.075 in. (1.9 mm). The casting core is secured within an aft chordwise portion of the airfoil defining section, and includes an aft end with an external radius measuring less than about 0.075 in. (1.9 mm). A cast component and a method for making the casting mold assembly are also disclosed.

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.