A method to manufacture reticulated metal foam via a dual investment, includes pre-investment of a precursor with a diluted pre-investment ceramic plaster then applying an outer mold to the encapsulated precursor as a shell-mold.

Casting core for the manufacture of hollow metal aeronautical parts, in particular high-pressure turbine parts by lost-wax casting, including a composite material including on the one hand a first phase of formula M.sub.n+1AlC.sub.n, where n=1 to 3 and M being a transition metal selected from the group consisting of titanium and/or niobium and/or molybdenum, the composite material including on the other hand a second phase of formula Al.sub.4C.sub.3.

Casting core for the manufacture of hollow metal aeronautical parts, in particular high-pressure turbine parts by lost-wax casting, including a composite material including on the one hand a first phase of formula M.sub.n+1AlC.sub.n, where n=1 to 3 and M being a transition metal selected from the group consisting of titanium and/or niobium and/or molybdenum, the composite material including on the other hand a second phase of formula Al.sub.4C.sub.3.

Molding core for manufacturing an OMC hollow aeronautical part, in particular a fan module part, including a composite material including on the one hand a first phase of formula M.sub.n+1AlC.sub.n, where n=1 to 3, and M being a transition metal selected from the group consisting of titanium, niobium, chromium or zirconium, the composite material including on the other hand a second phase of formula Al.sub.4C.sub.3

The present invention provides a method for making internal passages for use in investment casting processes, especially for gas turbine components such as blades or vanes. The apparatus comprises a first mold cavity having grooves formed therein, a second mold cavity having a shape complementary to the final casting design and ceramic cores. Each groove of the first mold cavity has a depth equal to a radius of certain number of ceramic cores which correspond to cooling channels. The ceramic cores are placed in the first mold cavity and fugitive wax is injected for temporary positioning of the cores. Two fugitive wax segments are formed about the cores. The fugitive segments locate the ceramic cores in the second mold cavity, and wax is injected about the cores and locating segments to form a pattern for investment casting process.

The present disclosure generally relates to partial integrated core-shell investment casting molds that can be assembled into complete molds. Each section of the partial mold may contain both a portion of a core and portion of a shell. Each section can then be assembled into a mold for casting of a metal part. The partial integrated core-shell investment casting molds and the complete molds may be provided with filament structures corresponding to cooling hole patterns on the surface of the turbine blade or the stator vane, which provides a leaching pathway for the core portion after metal casting. The invention also relates to core filaments that can be used to supplement the leaching pathway, for example in a core tip portion of the mold.

The present disclosure generally relates to integrated core-shell investment casting molds that provide filament structures corresponding to cooling hole patterns in the surface of the turbine blade or stator vane, which provide a leaching pathway for the core portion after metal casting. These filament structures may be linear or non-linear. The invention also relates to core filaments that can be used to supplement the leaching pathway, for example in a core tip portion of the mold.

The present disclosure generally relates to integrated core-shell investment casting molds that provide an indentation structure corresponding to a thin root component of the turbine blade or vane (i.e. angel wing, skirt, damper lug).

The present disclosure generally relates to integrated core-shell investment casting molds that provide filament structures corresponding to cooling hole patterns on the surface of the turbine blade or stator vane, which provide a leaching pathway for the core portion after metal casting. The invention also relates to core filaments that can be used to supplement the leaching pathway, for example in a core tip portion of the mold.

The present disclosure generally relates to integrated core-shell investment casting molds including a main core portion, a core tip portion, and a shell portion with at least one cavity between the core portion and the shell portion. The cavity defines the shape of a cast component upon casting and removal of the ceramic mold. These molds also provide filament structures corresponding to cooling hole patterns in the surface of the turbine blade or the stator vane, which provide a leaching pathway for the core portion after metal casting. At least two ceramic tip filaments connect the core tip portion and the shell portion and eliminate the need for tip pins or a shell lock to hold the tip plenum core in place during casting. The invention also relates to core filaments that can be used to supplement the leaching pathway, for example in a core tip portion of the mold.