A mold for manufacturing a casted workpiece is, at least in-part, manufactured utilizing an additive manufacturing process. The mold may have a core having non-line-of-sight features that are additively manufactured and in contact with an outer shell of a wax mold and/or an outer shell of a casting mold of the mold. The outer shell of either the wax or casting molds may also be additively manufactured, and the shell of the casting mold may be additively manufactured as one unitary piece to the core.

An assembly for manufacturing a wax moulding of a turbine engine blade has a wax injection mould in which a core is able to be mounted in a predetermined moulding position, the core including a main element and at least a first secondary element each including at least one functional part and a non-functional part, wherein the non-functional part of the first secondary element includes a rod portion extending in a longitudinal direction of the blade and housed in a first slot of the non-functional part of the main member, the mould including a first internal boss clamping said rod portion at the bottom of the first slot.

An assembly for manufacturing a wax moulding of a turbine engine blade has a wax injection mould in which a core is able to be mounted in a predetermined moulding position, the core including a main element and at least a first secondary element each including at least one functional part and a non-functional part, wherein the non-functional part of the first secondary element includes a rod portion extending in a longitudinal direction of the blade and housed in a first slot of the non-functional part of the main member, the mould including a first internal boss clamping said rod portion at the bottom of the first slot.

A core element of an investment core for use in a casting process used to produce an airfoil includes an investment core body, an extension connected to and protruding from the investment core body, and a connection portion connected to the investment core body and to the extension. The investment core body comprises a ceramic material. A shape of the extension comprises a tube with a centerline axis passing through a center of the extension. A shape of a cross-section of the extension taken along a plane perpendicular to the extension centerline axis comprises an ellipse. The extension is connected to the investment core body by the connection portion.

An airfoil includes a multi-part body and one or more thermally conductive pins. The multi-part body has an interior region and is formed from multiple pieces joined with each other at an interface. The pieces have multiple cavities and at least one of the pieces defines airfoil cooling channels disposed within the interior region of the body. The one or more thermally conductive pins are within the interior region of the body and extend across the interface. Each of the thermally conductive pins has a first segment disposed within a corresponding cavity of a first piece of the multiple pieces and a second segment disposed within a corresponding cavity of a second piece of the multiple pieces.

Supports for supporting mould parts and/or cores in investment casting, comprise support material comprising: a mechanically supportive continuous matrix phase comprising alumina; at least one second phase interpenetrating the matrix phase and providing a pathway for leachants to penetrate into the material; wherein the support material comprises: in the range of 1 wt % and 12 wt % of the second phase; and less than 15 vol % voids.

Supports for supporting mould parts and/or cores in investment casting, comprise support material comprising: a mechanically supportive continuous matrix phase comprising alumina; at least one second phase interpenetrating the matrix phase and providing a pathway for leachants to penetrate into the material; wherein the support material comprises: in the range of 1 wt % and 12 wt % of the second phase; and less than 15 vol % voids.

The present invention relates to a foundry core, which has the base form of a hollow body, with the foundry core being formed from a moulding material consisting of a mixture which is formed from a moulding sand and a binder and optionally from additives added to set its properties and a method for its manufacture. The foundry core according to the invention can be easily manufactured. This is achieved as a result of the foundry core being divided into at least two sub-segments and forming elements interacting with one another in a positive-locking manner being provided on the edge sides, with which sub-segments arranged adjacent to one another abut on one another, or in proximity to these edge sides, via which forming elements the sub-segments arranged adjacent to one another are fixed by positive locking immovably against one another at least in one direction.

The invention provides a method of assembling together a first core (12) and a second core (14) in order to make a non-permanent model configured for use in lost wax molding to form a part having a first cavity and a second cavity corresponding respectively to the first core and to the second core. The invention is characterized by the fact that the first and second cores (12, 14) are assembled together with a first spacer (20), the first spacer (20) being arranged between the first and second cores.

The invention provides a method of assembling together a first core (12) and a second core (14) in order to make a non-permanent model configured for use in lost wax molding to form a part having a first cavity and a second cavity corresponding respectively to the first core and to the second core. The invention is characterized by the fact that the first and second cores (12, 14) are assembled together with a first spacer (20), the first spacer (20) being arranged between the first and second cores.