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 for manufacturing a shell mold for the production by lost-wax casting of bladed elements (1) of an aircraft turbine engine, including the following steps: creating an assembly (200) including a wax pattern (100) as well as a device for forming a cup for pouring metal (32b) and having an end surface (40a); depositing a hot wax coating layer on at least one portion of the end surface (40a); forming the shell mold around the assembly (200). In addition, the method includes, between steps b) and c), the implementation of a step of structuring the coating layer intended for reinforcing the adhesion between the layer (46) and the shell mold, and including the production of recesses (62) and projections (60) on the still-malleable coating layer.

A method of manufacturing a component includes forming a mould assembly including an initial mould unit, providing a seed crystal including a primary growth direction, determining an optimal angular orientation of the unit, rotating the unit to dispose the unit's optimal angular orientation, encasing the unit in a refractory material, and forming a refractory mould unit having a component mould including a mould wall defining a mould cavity, and a seed holder. In the optimal angular orientation, the seed crystal's primary growth direction is angled away from the wall, thereby forming a converging disposition with the wall in a of the wall's first region facing the central sprue and a diverging disposition with the wall in the wall's second region facing a mould heater. The method includes receiving the seed crystal within the seed holder and filling the mould cavity with molten castable material to form the component.

A method of forming a cast component and a method of forming a casting mold. The method is performed by connecting at least one wax gate component to a ceramic core-shell mold. The ceramic core-shell mold includes at least a first core portion, a first shell portion, and a second shell portion, wherein the first shell portion is adapted to interface with at least the second shell portion to form at least one first cavity between the core portion and the first and second shell portions. The core-shell mold may be inspected and assembled prior to connection of the wax gate component. At least a portion of the ceramic core-shell mold and the wax gate component is coated with a second ceramic material. The wax gate component is then removed to form a second cavity in fluid communication with the first cavity.

A method of manufacturing a component includes forming a mould assembly including an initial mould unit, providing a seed crystal including a primary growth direction, determining an optimal angular orientation of the unit, rotating the unit to dispose the unit's optimal angular orientation, encasing the unit in a refractory material, and forming a refractory mould unit having a component mould including a mould wall defining a mould cavity, and a seed holder. In the optimal angular orientation, the seed crystal's primary growth direction is angled away from the wall, thereby forming a converging disposition with the wall in a of the wall's first region facing the central sprue and a diverging disposition with the wall in the wall's second region facing a mould heater. The method includes receiving the seed crystal within the seed holder and filling the mould cavity with molten castable material to form the component.

Methods and materials for forming a three-dimensional (3D) structure in a material are described. An example method includes directing a liquid casting material into a mold cavity of a mold structure, where the mold cavity corresponds to a three-dimensional (3D) structure. The method further includes causing the liquid casting material to solidify within the mold cavity to form a solid structure of the casting material, removing at least a portion of the mold structure from the solid structure of the casting material, and forming a structural material around the solid structure of the casting material. The solid casting material is liquified within the structural material. The liquified casting material is evacuated from the structural material to form the 3D structure in the structural material.

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 refractory mold is disclosed. The refractory mold includes a fugitive pattern assembly comprising a hollow sprue that comprises a sprue wall disposed about a longitudinal axis; a pattern disposed outwardly of the sprue wall; and an outwardly extending gate attached to and extending between the sprue wall and the pattern, the hollow sprue, pattern and gate each formed from a fugitive material; and a refractory mold formed on and having a mold cavity defined by an outer surface of the fugitive pattern assembly.

The invention relates to the field of monocrystalline casting, and more specifically to a mold (1) for monocrystalline casting, and also to fabricating and using the mold. In particular, the mold (1) presents a mold cavity (7) comprising a first volume (7a), a second volume (7b) and a grain duct (4). The second volume (7b) is situated on the first volume (7a), being in communication therewith, and includes at least one horizontal projection relative to the first volume (7a). The grain duct (4) has a bottom end (4a) connected to the first volume (7a) and a top end (7b) adjacent to said horizontal projection of the second volume (7b). The mold (1) also has a separator member (11) interposed between the second volume (7b) of the mold cavity (7) and the top end (4b) of the grain duct (4).

A method for manufacturing a high-strength golf iron head with a thin striking faceplate includes placing a shell mold onto a rotary table. At least one metal ingot is placed into a crucible portion of the shell mold and melts in a vacuum environment. The rotary table rotates to cause the molten metal to flow into a cavity portion of the shell mold. The rotating shaft is slowly stopped, and the shell mold is removed after pouring. The shell mold is destroyed after the molten metal cools and solidifies, obtaining a casting. A cast product portion is separated from the casting to obtain at least one golf iron head subsequently treated with heat treatment to provide a striking faceplate of the golf iron head with a tensile strength of 280-340 ksi, an elongation of 4%-20%, and a minimum thickness of 1.4-1.8 mm excluding a groove depth of the striking faceplate.