A casting method includes: forming a seed, the seed having a first end and a second end, the forming including bending a seed precursor; placing the seed second end in contact or spaced facing relation with a chill plate; contacting the first end with molten material; and cooling and solidifying the molten material so that a crystalline structure of the seed propagates into the solidifying material. The forming further included reducing a thickness of the seed proximate the first end relative to a thickness of the seed proximate the second end.

A molding system includes a mold and a fluid delivery system. The mold includes a fluid permeable material that defines a mold cavity and is permeable to a cooling fluid. The mold is configured to mold a molten material arranged in the mold cavity. The fluid delivery system is in fluid communication with the fluid permeable material, and is configured to deliver the cooling fluid via nozzles to the fluid permeable material. When the molten material is arranged in the mold cavity, the fluid delivery system delivers the cooling fluid to the fluid permeable material at a delivery pressure that is intentionally varied, such that the cooling fluid permeates through the fluid permeable material to cool and solidify the molten material arranged in the mold cavity to form a solidified outer skin. The delivery pressure may be varied, e.g. increased, as a thickness of the solidified outer skin increases.

A process for high integrity castings of metals and their alloys includes the steps of providing at least a sand mold at desired elevated temperatures, delivering a molten metal into the mold, and supplying a predetermined amount of coolant to contact the surfaces of the casting at desired rates, times, and durations to achieve an acceptable level of progressive solidification from the distal end of the casting towards the riser until the casting has reached desired temperatures.

A cast part includes an outermost wall, at least one inner wall defining at least two internal passages and at least one cast cooling fin extending from an outer surface. The cooling fin includes a ratio of fin height to an average fin thickness that is greater than 2.0 and no more than 18.0. A method is also disclosed.

A casting method includes: forming a seed, the seed having a first end and a second end, the forming including bending a seed precursor; placing the seed second end in contact or spaced facing relation with a chill plate; contacting the first end with molten material; and cooling and solidifying the molten material so that a crystalline structure of the seed propagates into the solidifying material. The forming further included reducing a thickness of the seed proximate the first end relative to a thickness of the seed proximate the second end.

A casting method includes forming a seed. The seed has a first end and a second end. The forming includes bending a seed precursor. The seed second end is placed in contact or spaced facing relation a chill plate. The first end is contacted with molten material. The molten material is cooled and solidifies so that a crystalline structure of the seed propagates into the solidifying material. The forming further includes inserting the bent seed precursor into a sleeve leaving the bent seed precursor protruding from a first end of the sleeve.

A casting method includes forming a seed. The seed has a first end and a second end and an inner diameter (ID) surface and an outer diameter (OD) surface. The seed second end is placed in contact or spaced facing relation with a chill plate. The first end is contacted with molten material. The molten material is cooled and solidified so that a crystalline structure of the seed propagates into the solidifying material. At least a portion of the seed contacted with the molten material has a solidus higher than a solidus of at least an initial pour portion of the molten material.

A mould for use in manufacturing a single-crystal component by metal casting and epitaxial growth, includes a cavity in which the component is to be formed and a housing having an elliptical cross-section in which a single-crystal seed is disposed, the seed having an elliptical cross-section defined by a minor axis and by a major axis, the housing being in fluid communication with the cavity via an opening of circular cross-section through which molten metal is to flow, the single-crystal seed and the opening being centred on the same vertical axis, in which the minor axis and the major axis of the cross-section of the seed are oriented as a function of the secondary crystallographic orientations of the single-crystal forming the single-crystal seed.

The application belongs to the technical field of a casting mold and provides a side mold and a low-pressure hub casting mold. Channels of a cooling loop are processed in a back cavity of a side mold frame, a distance between the channels along a solidification direction of a casting gradually increases, and a cooling medium flows along the cooling loop, the ability of taking away heat changes from strong to weak, and a larger temperature gradient of the side mold may be formed by superposition with a temperature gradient formed by the thickness of the side mold.

A casting method includes forming a seed. The seed has a first end and a second end. The forming includes bending a seed precursor. The seed second end is placed in contact or spaced facing relation a chill plate. The first end is contacted with molten material. The molten material is cooled and solidifies so that a crystalline structure of the seed propagates into the solidifying material. The forming further includes inserting the bent seed precursor into a sleeve leaving the bent seed precursor protruding from a first end of the sleeve.