A method locates and maintains a core in fixed space relationship within the interior of a shell mould. The method provides at least one pin extending into the core with at least one axial end of the pin protruding from the core. A wax pattern having an outer surface is formed by encasing the core and at least one protruding axial end of the pin in wax such that at least one protruding axial end of the pin terminates at the outer surface of the wax pattern. A shell mould is formed around the wax pattern such that, upon removal of the wax pattern, and in a subsequent casting process for production of hollow metal components, at least one protruding axial end of the pin abuts the shell mould, thus fixing the pin and maintaining a position of the core relative to the mould. The protruding axial end of the pin has an enlarged head.

A core for an airfoil casting, including: a cantilevered core section; and a boss extending from the cantilevered core section to an outer profile of the core.

A core for an airfoil casting, including: a cantilevered core section; and a boss extending from the cantilevered core section to an outer profile of the core.

An end or intermediate casing for a combustion turbine engines includes prefabricated vanes of a first metal. Ends of the prefabricated vanes are then embedded within cast-in place inner and outer, annular-shaped ring castings, formed from a second metal having a lower melting point than the first metal. The respective ends of the prefabricated vanes include first and second shanks, with respective first and second surface features that are oriented transverse to the central axis of the vane are encapsulated in the molten second metal during the inner and outer ring casting. Once the castings harden, the first and second surface features, such as for example circumferential fillets projecting outwardly from the airfoil portion of the vane, inhibit separation of the vanes from the respective inner and outer rings.

There is disclosed herein a method of designing a mold, the mold being at least part of a unitary body to be formed from a plurality of layers by 3D printing, the method including defining an inner surface of the mold corresponding to at least part of an outer surface of an object to be molded in the mold; selecting a first material from which at least part of the mold is to be printed; and selecting a second material from which at least another part of the mold is to be printed, the second material having a higher thermal and/or electrical conductivity than the first material, wherein at least one of the layers from which the mold is to be formed by 3D printing includes areas to be printed from each of the first and second materials.

There is disclosed herein a method of designing a mold, the mold being at least part of a unitary body to be formed from a plurality of layers by 3D printing, the method including defining an inner surface of the mold corresponding to at least part of an outer surface of an object to be molded in the mold; selecting a first material from which at least part of the mold is to be printed; and selecting a second material from which at least another part of the mold is to be printed, the second material having a higher thermal and/or electrical conductivity than the first material, wherein at least one of the layers from which the mold is to be formed by 3D printing includes areas to be printed from each of the first and second materials.

A method for making a wax model for the manufacture of a part, the part including at least one cavity, the method including: arranging at least two core elements made of a ceramic material into a wax mold, the core elements having at least partially a shape complementary to the cavity of the part to be manufactured, and injecting wax into the wax mold, around the core elements, so as to form the wax model, the two core elements being assembled prior to the injection of wax by at least one staple, the staple including a central portion from which two branches extend, each branch being fitted into an orifice formed in one of the core elements.

A method for making a wax model for the manufacture of a part, the part including at least one cavity, the method including: arranging at least two core elements made of a ceramic material into a wax mold, the core elements having at least partially a shape complementary to the cavity of the part to be manufactured, and injecting wax into the wax mold, around the core elements, so as to form the wax model, the two core elements being assembled prior to the injection of wax by at least one staple, the staple including a central portion from which two branches extend, each branch being fitted into an orifice formed in one of the core elements.

A moulding device (1) for moulding a material around a core (2), comprising a hollow moulding enclosure (3) suitable for receiving the core (2), and means for controlling the shape of the core (2) in the hollow enclosure (3), the control means comprising means for deforming the core (2). The control means further comprise force control means and a control unit (8) suitable for actuating the deformation means in accordance with information provided by the force control means.

An assembly of core components is provided for investment casting. First core component has an arrangement of pedestals and second core component has an arrangement holes. The first and second core components are assembled to mate in a required positional relationship. Pedestals 106 extend through the holes so that a protruding portion of each pedestal protrudes from the hole. A moulding material is applied to encapsulate the protruding portions of the pedestals to secure the pedestals with respect to the holes and thereby to secure the first core component with respect to the second core component.