A method and casting core for forming a landing for welding a baffle inserted into an airfoil are disclosed, wherein the baffle landing of the blade or vane is formed in investment casting by the casting core rather than by wax, reducing tolerances and variability in the location of the baffle inserted into the cooling cavity of airfoil when the baffle is welded to the baffle landing.

A method and casting core for forming a landing for welding a baffle inserted into an airfoil are disclosed, wherein the baffle landing of the blade or vane is formed in investment casting by the casting core rather than by wax, reducing tolerances and variability in the location of the baffle inserted into the cooling cavity of airfoil when the baffle is welded to the baffle landing.

A method for manufacturing a blade with a first portion and a second portion, the method includes forming the first portion that includes forming a model of the first portion from removable material, forming a first shell mould from the model of the first portion, and forming the single-crystal or columnar first portion m a first metal alloy in the first shell mould from a single-crystal seed, and forming the second portion in which the second portion is formed on the first portion, and in which the first portion and the second portion are made from different materials, the second portion being polycrystalline and formed from a second metal alloy. The blade includes a single-crystal or columnar first portion made from a first metal alloy and a polycrystalline second portion made from the second metal alloy different from the first metal alloy.

A medical scope device such as an endoscope is produced using a cast aluminum process including a molten casting aluminum alloy including a maximum of 0.2 - 0.3% Si and at least 5% Zn. The process includes providing an investment casting mold, casting the aluminum alloy in the mold to create a component and removing the mold from the component, post-machining the component to meet a desired specification, and after post-machining the component, performing surface finishing, such as centrifugal barrel finishing (CBF) sufficient to remove impurities on casting surfaces by 2 - 3 mils, then coating the component with a micro-crystalline aluminum anodic coating of at least 0.5 mil thickness. A medical scope and product-by-process is also provided employing such techniques.

A foundry mold includes at least one molding cavity and one pair of feeder arms. The molding cavity extends, along a horizontal axis, from a first end to a second end, and the first pair of feeder arms comprises a first feeder arm, oriented in a substantially vertical direction and connected to the first end of the first molding cavity, and a second feeder arm, substantially parallel to the first feeder arm and connected to the second end of the first molding cavity.

A method of forming a cast component and a method of forming a casting mold is described herein. The ceramic core-shell mold includes at least first core portion, a first shell portion, and at least one first cavity between the core portion and the first shell portion. The core-shell mold may be manufactured using an additive manufacturing process and may include an integrated ceramic filter. 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 forming a cast component and a method of forming a casting mold is described herein. The ceramic core-shell mold includes at least first core portion, a first shell portion, and at least one first cavity between the core portion and the first shell portion. The core-shell mold may be manufactured using an additive manufacturing process and may include an integrated ceramic filter. 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 fabricating a casting, the method including applying a substrate to a sacrificial mold, the sacrificial mold including a shaped non-planar receiving surface to receive the substrate and provide a casting of the substrate having a shaped structure corresponding to the receiving surface; and subjecting the sacrificial mold and casting to freeze drying conditions and sublimating the sacrificial mold from the casting to form a cast article including the shaped non-planar structure.

A method of fabricating a casting, the method including applying a substrate to a sacrificial mold, the sacrificial mold including a shaped non-planar receiving surface to receive the substrate and provide a casting of the substrate having a shaped structure corresponding to the receiving surface; and subjecting the sacrificial mold and casting to freeze drying conditions and sublimating the sacrificial mold from the casting to form a cast article including the shaped non-planar structure.

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.