The present disclosure generally relates to casting molds including a casting core comprising a first metal component and a second metal component. In an aspect, the first metal component has a lower melting point than the second metal component. In another aspect, the second metal component surrounds at least a portion of the first metal component and defines a cavity in the casting core when the first metal component is removed and the second metal component is not removed.

The present disclosure generally relates to casting molds including a casting core comprising a first metal component and a second metal component. In an aspect, the first metal component has a lower melting point than the second metal component. In another aspect, the second metal component surrounds at least a portion of the first metal component and defines a cavity in the casting core when the first metal component is removed and the second metal component is not removed.

The present disclosure generally relates to investment casting molds comprising a casting core comprising at least one graded core component, the graded core component comprising at least one graded transition between a first core material and a second core material.

The present disclosure generally relates to investment casting molds comprising a casting core comprising at least one graded core component, the graded core component comprising at least one graded transition between a first core material and a second core material.

Aspects of the disclosure generally relate to a casting mold for forming a cast part. The casting mold includes a casting shell having an internal surface bounding an interior, and a casting core positioned within the interior to define a cavity between the casting core and the casting shell, whereby the internal surface of the casting shell defines an outer surface of the cast part.

Aspects of the disclosure generally relate to a casting mold for forming a cast part. The casting mold includes a casting shell having an internal surface bounding an interior, and a casting core positioned within the interior to define a cavity between the casting core and the casting shell, whereby the internal surface of the casting shell defines an outer surface of the cast part.

A stack molding pattern and a shell for manufacturing aircraft turbine engine blades via lost wax casting. The stack molding shell includes a plurality of shell blade elements, each intended for producing a blade, wire elements being arranged within the shell blade elements; and a metal feeder including a plurality of metal outlets, each one radially open towards one of the shell blade elements and connected with the second end portion of the element. The shell includes a protective screen, associated with each second end portion and intended to protect a sensitive portion of the wire elements against the direct impact of a flow of metal from the feeder. The sensitive portion is located in the second end portion, downstream from the protective screen.

A stack molding pattern and a shell for manufacturing aircraft turbine engine blades via lost wax casting. The stack molding shell includes a plurality of shell blade elements, each intended for producing a blade, wire elements being arranged within the shell blade elements; and a metal feeder including a plurality of metal outlets, each one radially open towards one of the shell blade elements and connected with the second end portion of the element. The shell includes a protective screen, associated with each second end portion and intended to protect a sensitive portion of the wire elements against the direct impact of a flow of metal from the feeder. The sensitive portion is located in the second end portion, downstream from the protective screen.

Provided is a casting method using lost foam capable of forming a small highly-finished hole with a diameter of 18 mm or less and a length of 50 mm or more by casting. A casting method using lost foam of the present embodiment includes the steps of embedding, in foundry sand, a casting pattern formed by applying a mold wash with a thickness of 1 mm or more to a surface of the foam pattern, the foam pattern having a hole with a diameter of D (mm); replacing the foam pattern with molten metal by pouring the molten metal into the casting pattern and losing the foam pattern; and forming a casting having a small hole with a diameter of 18 mm or less and a length of 50 mm or more by cooling the molten metal, and the method satisfies the following formulas (0) and (1):

2<D≦19.7   Formula (0)

σc≧−0.36+140/D.sup.2   Formula (1) where σc (MPa) is transverse rupture strength (bending strength) of the mold wash that is heated to decompose resin constituting the mold wash and then returned to room temperature.

Provided is a casting method using lost foam capable of forming a small highly-finished hole with a diameter of 18 mm or less and a length of 50 mm or more by casting. A casting method using lost foam of the present embodiment includes the steps of embedding, in foundry sand, a casting pattern formed by applying a mold wash with a thickness of 1 mm or more to a surface of the foam pattern, the foam pattern having a hole with a diameter of D (mm); replacing the foam pattern with molten metal by pouring the molten metal into the casting pattern and losing the foam pattern; and forming a casting having a small hole with a diameter of 18 mm or less and a length of 50 mm or more by cooling the molten metal, and the method satisfies the following formulas (0) and (1):

2<D≦19.7   Formula (0)

σc≧−0.36+140/D.sup.2   Formula (1) where σc (MPa) is transverse rupture strength (bending strength) of the mold wash that is heated to decompose resin constituting the mold wash and then returned to room temperature.