A ceramic core includes sintered ceramic powder and a hole opening on a surface of the ceramic core and having an opening portion with a maximum size of 100 μm or less. A manufacturing method for a ceramic core includes: preparing an injection molding composition by mixing ceramic powder and a binder; manufacturing a ceramic compact by performing the injection molding of the injection molding composition; and manufacturing a ceramic core by sintering the ceramic compact, wherein cumulative percentage of coarse powder with a particle diameter of more than 50 μm included in the ceramic powder is 30% or less on an integrated volume particle size distribution curve of the ceramic powder.

“A gypsum-based embedding material” is provided with which favorable casting can be conducted not only in the case where a conventional wax pattern is used, but also, in particular, in the case where a resin pattern different from the conventional wax pattern in disappearance temperature and disappearance behavior is used, and with which, although being a “gypsum-based embedding material”, occurrence of cracks, breakage, or the like in a mold is suppressed even when casting is conducted by “rapid heating” excellent in treatment efficiency. The gypsum-based embedding material composition for casting comprising, as main components, calcined gypsum as a binder, cristobalite and quartz as heat-expandable refractory materials, and a non-heat-expandable refractory material having an average particle diameter of 5 to 20 μm, the blending amount of the non-heat-expandable refractory material in 100 parts by mass of the main components being 10 to 25 parts by mass.

“A gypsum-based embedding material” is provided with which favorable casting can be conducted not only in the case where a conventional wax pattern is used, but also, in particular, in the case where a resin pattern different from the conventional wax pattern in disappearance temperature and disappearance behavior is used, and with which, although being a “gypsum-based embedding material”, occurrence of cracks, breakage, or the like in a mold is suppressed even when casting is conducted by “rapid heating” excellent in treatment efficiency. The gypsum-based embedding material composition for casting comprising, as main components, calcined gypsum as a binder, cristobalite and quartz as heat-expandable refractory materials, and a non-heat-expandable refractory material having an average particle diameter of 5 to 20 μm, the blending amount of the non-heat-expandable refractory material in 100 parts by mass of the main components being 10 to 25 parts by mass.

A method is provided for making a mold for casting advanced turbine airfoils (e.g. gas turbine blade and vane castings) which can include complex internal and external air cooling features to improve efficiency of airfoil cooling during operation in the gas turbine hot gas stream. The method steps involve incorporating at least one fugitive insert in a ceramic material in a manner to form a core and at least a portion of an integral, cooperating mold wall wherein the core defines an internal cooling feature to be imparted to the cast airfoil and the at least portion of the mold wall has an inner surface that defines an external cooling feature to be imparted to the cast airfoil, selectively removing the fugitive insert, and incorporating the core and the at least portion of the integral, cooperating mold wall in a mold for receiving molten metal or alloy cast in the mold.

A method is provided for making a mold for casting advanced turbine airfoils (e.g. gas turbine blade and vane castings) which can include complex internal and external air cooling features to improve efficiency of airfoil cooling during operation in the gas turbine hot gas stream. The method steps involve incorporating at least one fugitive insert in a ceramic material in a manner to form a core and at least a portion of an integral, cooperating mold wall wherein the core defines an internal cooling feature to be imparted to the cast airfoil and the at least portion of the mold wall has an inner surface that defines an external cooling feature to be imparted to the cast airfoil, selectively removing the fugitive insert, and incorporating the core and the at least portion of the integral, cooperating mold wall in a mold for receiving molten metal or alloy cast in the mold.

A method of fabricating an investment casting mold includes using a zircon-containing slurry to form a facecoat of a refractory investment wall of a mold cavity in an investment casting mold. The zircon-containing slurry includes, by weight, at least 70% of zircon powder. Also disclosed is a slurry for use in an investment casting mold. The slurry includes, by weight, at least 70% of zircon powder, 10%-30% of colloidal silica material, and 1%-10% of a carrier solvent. The method and slurry can be used to fabricate an investment casting mold that has a refractory investment wall with a facecoat having, by weight, at least 70% zircon.

A method of fabricating an investment casting mold includes using a zircon-containing slurry to form a facecoat of a refractory investment wall of a mold cavity in an investment casting mold. The zircon-containing slurry includes, by weight, at least 70% of zircon powder. Also disclosed is a slurry for use in an investment casting mold. The slurry includes, by weight, at least 70% of zircon powder, 10%-30% of colloidal silica material, and 1%-10% of a carrier solvent. The method and slurry can be used to fabricate an investment casting mold that has a refractory investment wall with a facecoat having, by weight, at least 70% zircon.

A method for manufacturing a compressor impeller wherein the compressor impeller is cast using a mold. As a first alternative, the mold is made using 3D printing. As a second alternative, a model of the compressor impeller is made using 3D printing, and the mold is then made on the basis of said model.

A method for manufacturing a compressor impeller wherein the compressor impeller is cast using a mold. As a first alternative, the mold is made using 3D printing. As a second alternative, a model of the compressor impeller is made using 3D printing, and the mold is then made on the basis of said model.

An investment casting system includes a core having at least one fine detail, a shell positioned relative to said core, and a strengthening coating applied at least to the at least one fine detail.