A molding tool (10) for manufacturing cooling features in a ceramic core for a casting process includes a first mold portion (12) comprising a crossover hole forming feature (18); a second mold portion (24) comprising an impingement jet receiving forming feature (30) for forming an impingement jet receiving feature having a desired aiming point (32); and a sacrificial alignment member (34) for extending at least partially into the crossover hole forming feature (18) at least partially into the aiming point (32) of the impingement jet receiving forming feature (30) for substantially aligning a central axis (38) of the crossover hole forming feature (18) with the aiming point (32) to maintain a crossover hole and aiming point alignment during casting to ensure that the jet is directed at the aiming point (32) in a resultant cast part.

A directional solidification casting method includes fluidly coupling a feed line conduit with a source of molten metal and with a directional solidification mold at a gating. The mold has an interior chamber with a shape of an object to be cast using directional solidification in a growth direction. The feed line conduit is fluidly coupled with the gating in a downward direction oriented at an angle that is closer to the growth direction of the mold than to another direction that is perpendicular to the growth direction of the mold. The method also includes positioning a downstream portion of the feed line conduit below the gating, directing the molten metal into the mold via the feed line conduit, and casting the object in the mold using directional solidification.

A cooling apparatus provided in a casting mold part formed with a cooler insertion hole in a die casting mold may include a cooler head including a coolant supply connector and a coolant exhaust connector, an internal pipe fixed to the cooler head to be fluidically-connected to the coolant supply connector, and integrally formed with a spiral protrusion over a predetermined range from a front end portion toward a rear end portion, and an external pipe fixed to the cooler head to be fluidically-connected to the coolant exhaust connector while holding a portion of a remaining range of the internal pipe, and configured to be coupled with an internal circumferential surface of the cooler insertion hole.

A casting device includes a mold provided with an insert die, a molten metal supply device for supplying molten metal into the mold, and a gas supply mechanism for supplying a gas, which is used for forced cooling, to the insert die. The insert die is made of tungsten having a thermal conductivity significantly higher than that of die steel. The insert die has a spiral or meandering gas passage therein. The spiral or meandering gas passage has a passage length much longer than a straight passage.

A molding tool (10) for manufacturing cooling features in a ceramic core for a casting process includes a first mold portion (12) comprising a crossover hole forming feature (18); a second mold portion (24) comprising an impingement jet receiving forming feature (30) for forming an impingement jet receiving feature having a desired aiming point (32); and a sacrificial alignment member (34) for extending at least partially into the crossover hole forming feature (18) at least partially into the aiming point (32) of the impingement jet receiving forming feature (30) for substantially aligning a central axis (38) of the crossover hole forming feature (18) with the aiming point (32) to maintain a crossover hole and aiming point alignment during casting to ensure that the jet is directed at the aiming point (32) in a resultant cast part.

An integrated module for a vehicle suspension includes a bearing outer ring and a suspension upright or knuckle, the outer ring being formed of a first high-strength material, and at least part of the suspension upright or knuckle being made from a second, metallic material, the second material being lighter than the first material. The upright or knuckle is co-moulded radially onto the outside of the bearing and is directly fixed to the bearing ring by means of an interface for form coupling. Opposite axial ends of the bearing outer ring are configured to receive closing and sealing devices for protecting one or more races of the bearing outer ring during co-moulding and for removing heat from the races during co-moulding.

A thermal system for casting process includes a set of centralized infrastructure components. The centralized infrastructure components include a central fluid reservoir providing fluid to the entire system. A control system for the thermal system is configured to supply fluids to a plurality of fluid lines corresponding to a plurality of casting circuits at various temperatures. The control system generates fluids for a plurality of casting circuits at various temperatures by mixing a plurality of fluid sources at different ratios.

A molding system includes a mold and a fluid delivery system. The mold includes a fluid permeable material that defines a mold cavity and is permeable to a cooling fluid. The mold is configured to mold a molten material arranged in the mold cavity. The fluid delivery system is in fluid communication with the fluid permeable material, and is configured to deliver the cooling fluid via nozzles to the fluid permeable material. When the molten material is arranged in the mold cavity, the fluid delivery system delivers the cooling fluid to the fluid permeable material at a delivery pressure that is intentionally varied, such that the cooling fluid permeates through the fluid permeable material to cool and solidify the molten material arranged in the mold cavity to form a solidified outer skin. The delivery pressure may be varied, e.g. increased, as a thickness of the solidified outer skin increases.

A casting mold is provided with a cavity portion and an overflow portion, and the overflow portion is connected to a gas flow path (suction path). A valve (an on-off valve, a shut-off valve) is provided between the gas flow path and the overflow portion. A heating method for a casting mold includes a step of setting the pressure in the cavity portion to a second pressure by sucking gas in the overflow portion and in the cavity portion while the valve is kept open for a second time period shorter than a first time period during casting. The heating method further includes a step of heating the casting mold by supplying molten metal into the cavity portion set at the second pressure, and solidifying the molten metal.

A casting mold for a crankcase of an internal combustion engine includes a water jacket core which has a frame core and a cooling duct core. A land core is provided which is designed and positioned in such a way as to form a cooling duct in an inter-cylinder land of a crankcase. The land core is retained in the frame core and is, or can be, centered using a top core.