A method is provided for casting a component. Accordingly, data indicative of at least one location of a unitary core-shell mold which is susceptible to a stress concentration is received. An additive manufacturing process is employed to form the unitary core-shell mold defining a casting cavity. The unitary core-shell mold includes a shell wall defining an outer component shape and a core wall positioned inward of the shell wall. The core wall defines an inner component shape. The core wall and/or the shell wall defines at least one reinforcement recess adjacent to the at least one location which is susceptible to the stress concentration. Following the forming of the unitary core-shell mold, at least one support member is positioned within the reinforcement recess in contact with the at least one location. With the support member in place, the component is cast within the casting cavity.

An approach for supporting a wax pattern during investment casting. The approach described herein forms a support structure to support the wax pattern during investment casting. The support structure has a capping structure with a geometry that can match a profile of a lower region of the wax pattern, and at least one support brace extending outward from the support capping structure. The support structure can be placed on a surface of the lower region. The support capping structure can form a defined envelope to enclose the lower region of the wax pattern. The support structure is connected to a base plate by the support brace(s). The capping structure and the support brace(s) secure the wax pattern to the base plate and distribute the load of the wax pattern to maximize strength while minimizing the risk of a discontinuity in the wax or shell that could affect the casting process.

An approach for supporting a wax pattern during investment casting. The approach described herein forms a support structure to support the wax pattern during investment casting. The support structure has a capping structure with a geometry that can match a profile of a lower region of the wax pattern, and at least one support brace extending outward from the support capping structure. The support structure can be placed on a surface of the lower region. The support capping structure can form a defined envelope to enclose the lower region of the wax pattern. The support structure is connected to a base plate by the support brace(s). The capping structure and the support brace(s) secure the wax pattern to the base plate and distribute the load of the wax pattern to maximize strength while minimizing the risk of a discontinuity in the wax or shell that could affect the casting process.

Methods of manufacturing a golf club head with one or more stiffening members proximate the face, and particularly solid rods or a plate with one or more cutouts, is disclosed herein. One method includes the steps of preparing a wax mold of a golf club head including a plate stiffening member with excess material, casting the golf club head, and machining away the excess material. Another method includes the steps of casting a golf club body, providing a plate stiffening member, providing a face component such as a face cup, tack welding the plate stiffening member and the face component to the golf club body, and welding these parts together.

Methods of manufacturing a golf club head with one or more stiffening members proximate the face, and particularly solid rods or a plate with one or more cutouts, is disclosed herein. One method includes the steps of preparing a wax mold of a golf club head including a plate stiffening member with excess material, casting the golf club head, and machining away the excess material. Another method includes the steps of casting a golf club body, providing a plate stiffening member, providing a face component such as a face cup, tack welding the plate stiffening member and the face component to the golf club body, and welding these parts together.

Provided is a multicore. The multicore includes a first core, being made of a water-insoluble material, having a hollow formed in the first core and, having an opening formed at both ends of the first core and connected to the hollow, a second core, being made of a water-soluble material and disposed inside the hollow, and a coating layer, being configured to surround the first core to prevent at least a portion of the first core and the second core from being exposed to an outside. Further, the first core includes a plurality of spaces to allow a fluid supplied to an interior of the first core to flow toward the second core.

Provided is a multicore. The multicore includes a first core, being made of a water-insoluble material, having a hollow formed in the first core and, having an opening formed at both ends of the first core and connected to the hollow, a second core, being made of a water-soluble material and disposed inside the hollow, and a coating layer, being configured to surround the first core to prevent at least a portion of the first core and the second core from being exposed to an outside. Further, the first core includes a plurality of spaces to allow a fluid supplied to an interior of the first core to flow toward the second core.

A core structure for a providing a cooling passage in a gas turbine engine includes a core body that has a first passage core. The first passage core has a first width in a chord-wise direction near a first wall. A second width in the chord-wise direction near a second wall. A third width in the chord-wise direction between the first and second walls. The third width being smaller than the first and second widths to form an hourglass shape.

A core structure for a providing a cooling passage in a gas turbine engine includes a core body that has a first passage core. The first passage core has a first width in a chord-wise direction near a first wall. A second width in the chord-wise direction near a second wall. A third width in the chord-wise direction between the first and second walls. The third width being smaller than the first and second widths to form an hourglass shape.

A method for forming a wax model for the manufacture of turbine blades by lost-wax casting, in which a core is provided, a lower surface shell and an upper surface shell are positioned and bonded on either side of ducts of the core adjacent to the root, the core equipped with the lower surface shell and with the upper surface shell is positioned in an injection mold, wax is injected around the core equipped with the lower surface shell and with the upper surface shell, so as to form a wax model including a blade airfoil and a blade root including a fir tree, the lower surface shell and the upper surface shell being positioned around the core so as to form a portion of the fir tree of the wax model.