A method for producing a flexible tooling liner for casting a ceramic core is presented. The method includes the steps of producing a three-dimensional (3D) reference object representative of a ceramic core to be cast, disposing the reference object into a containment vessel configured to receive a liquid flexible tooling material, filling the containment vessel with the liquid tooling material so that the reference object is encapsulated by the liquid tooling material on the surface whose topography is intended to be imparted, allowing the liquid tooling material to cure, and separating the cured flexible tooling along a parting surface into opposing portions and removing the reference the reference object.

A manufacturing process for blades of a turbomachine, e.g. a gas turbine engine for an aircraft. In the process: a) a ceramic core piece that comprises at least two ceramic core elements and a clamping part that connects the ceramic core elements, is positioned in a wax forming device, subsequently; b) a molten wax material is applied to the outside of the ceramic core piece in the wax forming device and the wax is allowed to solidify, and subsequently; c) at least two turbomachine blades are cast using a crystallographically-oriented metal casting process and the wax and the ceramic core piece are removed.

An approach for supporting a wax pattern during investment casting. The approach described herein forms a support structure to support the wax pattern during investment casting. The support structure has a capping structure with a geometry that can match a profile of a lower region of the wax pattern, and at least one support brace extending outward from the support capping structure. The support structure can be placed on a surface of the lower region. The support capping structure can form a defined envelope to enclose the lower region of the wax pattern. The support structure is connected to a base plate by the support brace(s). The capping structure and the support brace(s) secure the wax pattern to the base plate and distribute the load of the wax pattern to maximize strength while minimizing the risk of a discontinuity in the wax or shell that could affect the casting process.

An approach for supporting a wax pattern during investment casting. The approach described herein forms a support structure to support the wax pattern during investment casting. The support structure has a capping structure with a geometry that can match a profile of a lower region of the wax pattern, and at least one support brace extending outward from the support capping structure. The support structure can be placed on a surface of the lower region. The support capping structure can form a defined envelope to enclose the lower region of the wax pattern. The support structure is connected to a base plate by the support brace(s). The capping structure and the support brace(s) secure the wax pattern to the base plate and distribute the load of the wax pattern to maximize strength while minimizing the risk of a discontinuity in the wax or shell that could affect the casting process.

A method of forming a casting with a flow passage may include filling a tubular pipe with a filler to form a smart core; inserting the smart core into a mold having a cavity corresponding to a shape of the casting to be formed; injecting a molten metal into the cavity through a casting process; and removing the filler from the smart core, wherein a hardness of the tubular pipe is 70 Hv or more.

An approach for supporting a wax pattern during investment casting. The approach described herein forms a support structure to support the wax pattern during investment casting. The support structure has a capping structure with a geometry that can match a profile of a lower region of the wax pattern, and at least one support brace extending outward from the support capping structure. The support structure can be placed on a surface of the lower region. The support capping structure can form a defined envelope to enclose the lower region of the wax pattern. The support structure is connected to a base plate by the support brace(s). The capping structure and the support brace(s) secure the wax pattern to the base plate and distribute the load of the wax pattern to maximize strength while minimizing the risk of a discontinuity in the wax or shell that could affect the casting process.

An approach for supporting a wax pattern during investment casting. The approach described herein forms a support structure to support the wax pattern during investment casting. The support structure has a capping structure with a geometry that can match a profile of a lower region of the wax pattern, and at least one support brace extending outward from the support capping structure. The support structure can be placed on a surface of the lower region. The support capping structure can form a defined envelope to enclose the lower region of the wax pattern. The support structure is connected to a base plate by the support brace(s). The capping structure and the support brace(s) secure the wax pattern to the base plate and distribute the load of the wax pattern to maximize strength while minimizing the risk of a discontinuity in the wax or shell that could affect the casting process.

A casting core assembly is disclosed herein. The casting core assembly comprises a casting core and a bumper assembly. The bumper assembly is disposed on an outer surface of the casting core. The bumper assembly comprises a receptacle and a metal apparatus. The metal apparatus may be a pin, a sphere, or the like.

A casting core assembly is disclosed herein. The casting core assembly comprises a casting core and a bumper assembly. The bumper assembly is disposed on an outer surface of the casting core. The bumper assembly comprises a receptacle and a metal apparatus. The metal apparatus may be a pin, a sphere, or the like.

A differential carrier case with an inserted pipe for high pressure casting may include a mold core into which a first end of a pipe is inserted, a mold core pin fixed to the mold core to fix the mold core and the first end of the pipe, a drive core pin inserted into a second end of the pipe, and a thick portion surrounding an outer portion of the pipe.