A method of forming a casting mold pattern that includes a core comprises mounting the core in a fixture such that the core is free of flexing imposed by the fixture. Material is removed from and/or added to a first and/or second mounting surface of the core. The core is then positioned in a die, and wax is conducted into the die to form the pattern. The amount of material removed from the first and/or second mounting surface is such that the core will be within a predetermined range of acceptable positions when the core is in the die with the first mounting surface engaging a first core locating surface of the die end with the second mounting surface engaging a second core locating surface of the die. The range of acceptable positions is determined relative to an ideal position of an ideal core.

A casting method of using 3D printing to make shell mold, comprising the following steps of: conducting computer-aided graphic design based on the product to be manufactured; importing the graphic design into the 3D printer to print a 3D shell mold; conducting a sintering process of the printed shell mold for solidifying thereof; using the sintered shell mold as a casting cavity, injecting a molten raw material into the shell mold for formation; in the end, taking out the whole shell mold and breaking the shell mold to obtain a cast product; reprocessing the cast product to obtain a finished product; wherein printing materials of the 3D printing are made of a liquid mixture of photosensitive resin and ceramic powder, thereby improving production efficiency and reducing labor intensity as well as pollution.

A casting method of using 3D printing to make shell mold, comprising the following steps of: conducting computer-aided graphic design based on the product to be manufactured; importing the graphic design into the 3D printer to print a 3D shell mold; conducting a sintering process of the printed shell mold for solidifying thereof; using the sintered shell mold as a casting cavity, injecting a molten raw material into the shell mold for formation; in the end, taking out the whole shell mold and breaking the shell mold to obtain a cast product; reprocessing the cast product to obtain a finished product; wherein printing materials of the 3D printing are made of a liquid mixture of photosensitive resin and ceramic powder, thereby improving production efficiency and reducing labor intensity as well as pollution.

The invention relates to the foundry field, and in particular to a foundry process comprising the preheating of a mold (1) up to a first temperature, the casting of a metal in the liquid state, at a second temperature above the first temperature, in the mold kept in a main furnace (100) at the first temperature since the preheating, the difference between the first temperature and second temperature being no more than 80° C., the cooling and solidification of the metal in the mold (1) kept in the main furnace (100) at a pressure of less than 0.1 Pa at least since the casting, the removal of the mold (1) from the main furnace (100), and the demolding of the solidified metal.

The invention relates to the foundry field, and in particular to a foundry process comprising the preheating of a mold (1) up to a first temperature, the casting of a metal in the liquid state, at a second temperature above the first temperature, in the mold kept in a main furnace (100) at the first temperature since the preheating, the difference between the first temperature and second temperature being no more than 80° C., the cooling and solidification of the metal in the mold (1) kept in the main furnace (100) at a pressure of less than 0.1 Pa at least since the casting, the removal of the mold (1) from the main furnace (100), and the demolding of the solidified metal.

A molding tool (10) for manufacturing cooling features in a ceramic core for a casting process includes a first mold portion (12) comprising a crossover hole forming feature (18); a second mold portion (24) comprising an impingement jet receiving forming feature (30) for forming an impingement jet receiving feature having a desired aiming point (32); and a sacrificial alignment member (34) for extending at least partially into the crossover hole forming feature (18) at least partially into the aiming point (32) of the impingement jet receiving forming feature (30) for substantially aligning a central axis (38) of the crossover hole forming feature (18) with the aiming point (32) to maintain a crossover hole and aiming point alignment during casting to ensure that the jet is directed at the aiming point (32) in a resultant cast part.

A molding tool (10) for manufacturing cooling features in a ceramic core for a casting process includes a first mold portion (12) comprising a crossover hole forming feature (18); a second mold portion (24) comprising an impingement jet receiving forming feature (30) for forming an impingement jet receiving feature having a desired aiming point (32); and a sacrificial alignment member (34) for extending at least partially into the crossover hole forming feature (18) at least partially into the aiming point (32) of the impingement jet receiving forming feature (30) for substantially aligning a central axis (38) of the crossover hole forming feature (18) with the aiming point (32) to maintain a crossover hole and aiming point alignment during casting to ensure that the jet is directed at the aiming point (32) in a resultant cast part.

Partial integrated core-shell investment casting molds that can be assembled into complete molds are provided herein. 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. Core filaments that can be used to supplement the leaching pathway, for example in a core tip portion of the mold are also provided herein.

Partial integrated core-shell investment casting molds that can be assembled into complete molds are provided herein. 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. Core filaments that can be used to supplement the leaching pathway, for example in a core tip portion of the mold are also provided herein.

Disclosed is a preparation method of a foamed aluminum special-shaped part. The preparation method comprises the following steps: S1, pressing wax molds; S2, making a shell; S3, carrying out smelting; S4, carrying out casting; and S5, vibrating the shell. Finally, the foamed aluminum special-shaped part is obtained for a preparation process of a foamed aluminum compound casting.