A hollow metal article can be fabricated by casting a molten metal alloy around a core, solidifying the molten metal alloy to form a metal article, and chemically removing the core from the metal article to form a hollow cavity in the metal article. The core includes a ceramic core body and an x-ray radiopaque coating disposed on the ceramic core body. A method for testing the hollow metal article includes submitting the hollow metal article to x-ray imaging and determining based upon the x-ray imaging whether any of the x-ray radiopaque coating of the core remains in the hollow metal article.

A method to manufacture reticulated metal foam via a dual investment solid mold, includes pre-investment of a precursor with a diluted pre-investment ceramic plaster then investing the encapsulated precursor with a ceramic plaster.

A method to manufacture reticulated metal foam includes coating a precursor in a molten wax to increase ligament thickness; and investment coating the molten wax coated precursor with a ceramic plaster.

A method for manufacturing a turbine engine blade (25) comprising a pressure side and a suction side separated from one another by an inner space for the circulation of cooling air, the blade (25) comprising a tip (S) with a closing wall (29) joining the pressure side and suction side walls in the region of this tip (S) in order to define a well shape, the closing wall including through-holes. The closing wall (29) obtained by moulding has a considerable nominal thickness with pits (36, 37) locally reducing this thickness at each through-hole in order to facilitate the removal by chemical etching of alumina rods defining the holes. Since the closing wall (29) thus has a large nominal thickness, it can then be machined in order to form raised patterns or complex shapes inside the well.

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.

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 system and methods are provided for removing core elements of cast components. In one embodiment, a method includes controlling a first high temperature autoclave cycle for a cast component in a vessel with a first solution concentration to remove at least a first portion of core elements, wherein the first solution concentration, temperature and pressure in the vessel are controlled to expose one or more casting pins in the cast component. The method may also include controlling a second high temperature autoclave cycle for the cast component in the vessel with second solution concentration, wherein the second solution concentration, temperature and pressure in the vessel during the second high temperature autoclave cycle are controlled to loosen one or more of the casting pins from the cast component, and controlling one or more low temperature autoclave cycles to remove core and casting pins from the cast component.

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.

A solution is provided and includes a strong base, a corrosion inhibitor, wherein the strong base is an alkali metal hydroxide, wherein the corrosion inhibitor is at least one of an organic acid having a-COOH functional group or an alkali metal salt of one of an organic acid having a-COOH functional group.

Integrated core-shell investment casting molds include a filament structure corresponding to a cooling hole pattern in the surface of the turbine blade, stator vane, or shroud.