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 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.

Foundry cores, which consist of a mould material mixed from a binder and a mould sand, as well as optionally added additives, that are moulded in a complex way or are optimised with regard to their quality and which are provided for casting cast parts, can be produced by: a) moulding the foundry core by introducing the mould material into a foundry core mould; b) hardening the mould material; c) removing the foundry core from the foundry core mould; d) heating the foundry core to a deformation temperature; e) deforming the heated foundry core by applying a deformation force to the foundry core; and f) cooling the foundry core.

A foundry mix includes a major amount of a foundry aggregate and an effective binding amount of a binder system. The binder system cures in the presence of sulfur dioxide and a free radical initiator. The binder system may include (1) 10 to 70 parts by weight of an epoxy novolac resin; (2) 0.5 to 10 parts by weight of resorcinol; (3) 20 to 70 parts by weight of a monomeric or polymeric acrylate; and (4) an effective amount of a free radical initiator. Notably, (1), (2), (3) and (4) are separate components or mixed with another of said components, provided (4) is not mixed with (3), where said parts by weight are based upon 100 parts of the binder system.

A method of producing an investment casting ceramic core is provided that includes: providing a core body consisting of a leachable material; surrounding the core body with a mold composition within a vessel, which mold composition is configured to solidify; leaching the core body from the mold composition subsequent to the mold composition solidifying, thereby leaving an internal cavity within the solidified mold composition; depositing a ceramic composition within the internal cavity of the solidified mold composition; sintering the ceramic composition to a solid ceramic core; and removing the solid ceramic core from the mold composition.

A method for producing molding sand includes mixing an artificial sand with a furan resin composition including a furan resin precursor, and mixing a curing agent with the artificial sand with which the furan resin composition is mixed, wherein the curing agent includes xylene sulfonic acid.

The present invention is a granular material that can be well recoated regardless of the type of the granular material, and enables a refractory aggregate in an unprinted portion to be used without any regeneration process, in the manufacture of a three-dimensional laminated and shaped mold. This granular material is a granular material for use in three-dimensional laminated mold shaping, and obtained by adding a material that causes a hydration reaction having a moisture absorbing function and generates a catalytic effect to a coating material mixed with or coated with an acid as a catalyst which activates and hardens an organic binder for binding the granular material.

The invention relates to a method for producing three-dimensionally layered shaped bodies by means of layer-by-layer construction using a resin component which contains at least one furane resin, and more than 5% by weight and less than 50% by weight monomer furfuryl alcohol, and an acid. The shaped bodies produced in this manner are suitable inter alia as casting molds and casting cores for metal casting.

The invention relates to a method for the layerwise construction of bodies comprising at least one novolac in a solid, free-flowing form; an isocyanate component and a first solvent as a liquid component to be printed, wherein the solvent according to a preferred embodiment of the invention also has a catalyst dissolved in the first solvent; a corresponding construction material mixture; a component system for producing the bodies by means of 3-D printing; and three-dimensional bodies produced according to this method in the form of molds and cores for metal casting.

A foundry mix includes a major amount of a foundry aggregate and an effective binding amount of a binder system. The binder system cures in the presence of sulfur dioxide and a free radical initiator. The binder system may include (1) 10 to 70 parts by weight of an epoxy novolac resin; (2) 0.5 to 10 parts by weight of resorcinol; (3) 20 to 70 parts by weight of a monomeric or polymeric acrylate; and (4) an effective amount of a free radical initiator. Notably, (1), (2), (3) and (4) are separate components or mixed with another of said components, provided (4) is not mixed with (3), where said parts by weight are based upon 100 parts of the binder system.