A brake carrier casting and a method of making a brake carrier casting. The brake carrier casting may have a first side portion and a second side portion that may be connected by a first bridge and a second bridge. The first side portion, second side portion, first bridge, and second bridge may define an opening of the brake carrier casting.

A core pack has at least two cores. The cores have chaplet sections that are oriented relative to one another and form a print. A chaplet is or can be placed on and/or against the print, thus allowing the cores to be secured relative to one another.

A parent bore cylinder block of an internal combustion, opposed-piston engine includes cooling passages that are formed using a 3-D printed casting core. The casting core can include portions that are ceramic. The parent bore cylinder block can include multiple cylinders, each cylinder with cooling passages and turbulence inducing features in those cooling passages, particularly surrounding the central portions of the cylinders.

A parent bore cylinder block of an internal combustion, opposed-piston engine includes cooling passages that are formed using a 3-D printed casting core. The casting core can include portions that are ceramic. The parent bore cylinder block can include multiple cylinders, each cylinder with cooling passages and turbulence inducing features in those cooling passages, particularly surrounding the central portions of the cylinders.

A method of manufacturing protruding cast in features (10). At least one core insert (12) is manufactured using small particle sizes. A bulk core body is manufactured using large particle sizes. The at least one core insert (12) and bulk core body are fully fired separately. The at least one core insert (12) is bonded with the bulk core body.

Aspects of the disclosure are directed to treating a substrate, the substrate including at least one of a refractory metal or a ceramic material, and depositing a media onto the treated substrate to generate a casting core. Embodiments include a fixture, a substrate located on the fixture, the substrate including at least one of a refractory metal or a ceramic material, and a delivery head that deposits media onto the substrate to generate a casting core. Aspects are directed to a core configured for casting a component, the core comprising: a substrate that includes at least one of a refractory metal or a ceramic material, and media deposited on the substrate, the media having a dimension within a range of between 0.5 and 500 micrometers.

A casting device having a casting mold and a core for producing a helical casting is described. The may have an expendable core that can be dissolved after the casting process. Advantageous effects of the device and process can be achieved by virtue of the fact that the female mold for accommodating the helical casting during the casting process is formed completely within the outer contour of the core, the female mold being delimited by the core and, at the peripheral boundary surfaces of the female mold, by the casting mold.

Methods for forming airfoils, core assemblies, and airfoils for gas turbine engines are described. The methods include forming an airfoil body about a core assembly configured to define one or more internal cavities of the airfoil body, the core assembly comprising at least core structure having a purge slot protrusion extending from a portion of the core structure, removing the core assembly from the airfoil body to form one or more internal cavities, wherein at least one internal cavity has a cavity extension define by the purge slot protrusion, and forming a squealer pocket in a tip of the formed airfoil body, wherein a cavity purge slot is formed at the cavity extension to fluidly connect the respect internal cavity with the squealer pocket.

In one exemplary embodiment, an airfoil includes pressure and suction side walls that extend in a chord-wise direction between leading and trailing edges. The pressure and suction side walls also extend in a radial direction to provide an exterior airfoil surface. A cooling passage is arranged between the pressure and suction walls. The cooling passage has a first width in the chord-wise direction near the suction side wall. A second width is in the chord-wise direction near the pressure side wall. A third width is between the pressure and suction side walls. The third width is smaller than the first and second widths.

A core assembly for a casting system according to an exemplary aspect of the present disclosure includes, among other things, a core that includes a body and at least one hole formed through the body and a spacer that extends through the at least one hole. The spacer includes a stud portion and a chaplet portion configured to abut a surface of the body that circumscribes the at least one hole.