A disposable core die is provided. The disposable core die includes a first portion defining an inlet configured to receive a slurry therethrough, a second portion integrally formed downstream from the first portion and configured to receive the slurry from the first portion, and a third portion integrally formed downstream from the second portion. The second portion includes a plurality of hollow tubes that are substantially coaxially aligned and have a wall thickness within a range defined between about 0.1 mm and about 0.5 mm, and the third portion defines an outlet configured to discharge excess slurry from the second portion.

A slurry for forming a mold includes a silica sol as a dispersion medium and niobia-stabilized zirconia dispersed in the silica sol.

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.

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 wax pattern surface-treating agent includes a solvent, boron nitride, and at least one surfactant selected from a group consisting of an anionic surfactant, a cationic surfactant, a non-ionic surfactant, and an amphoteric surfactant.

An airfoil is disclosed. The airfoil may comprise a leading edge, a body portion and a trailing edge formed from a high-modulus plating. The body portion of the airfoil may be formed from a material having a lower elastic modulus than the high-modulus plating. The high-modulus plating may improve the stiffness of the trailing edge, allowing for thinner trailing edges with improved fatigue life to be formed.

A composite component and a plated polymer component are disclosed. The composite component may comprise a body portion formed from an organic matrix composite, a first metal coating applied to a surface of the body portion, and an outer metal layer on the first metal coating that is erosion-resistant. The plated polymer component may comprise a polymer substrate, a metal plating layer applied to a surface of the polymer substrate, and at least one selectively thickened region in the metal plating layer. The at least one selectively thickened region may assist in protecting the plated polymer component against wear and/or erosion.

Compositions useful for foundry processes such as green sandcasting are discussed. The compositions may comprise ball clay, bentonite, and a carbonaceous material. The ball clay may comprise leonardite and/or causticized lignite, e.g., as a portion of the natural ball clay deposit. The composition may further comprise sand, such that the resulting mixture may be formed into a green sand mold for use in casting molded articles. Incorporation of ball clay materials in the compositions may help to improve the quality of the casted article.

Aspects of the disclosure are directed to a method comprising obtaining a refractory metal core (RMC), installing the RMC inside a tool, and subsequent to installing the RMC inside the tool, injecting a slurry into the tool to form a composite body from the RMC and the slurry. Aspects of the disclosure are directed to a composite body, comprising: a refractory metal core (RMC), and a slurry that at least partially encapsulates the RMC.

A disposable core die includes a first portion defining an inlet configured to receive a slurry therethrough, a second portion integrally formed downstream from the first portion and configured to receive the slurry from the first portion, and a third portion integrally formed downstream from the second portion. The second portion includes a plurality of hollow tubes that are substantially coaxially aligned and have a wall thickness within a range defined between about 0.1 mm and about 0.5 mm, and the third portion defines an outlet configured to discharge excess slurry from the second portion.