A core forming method is provided for forming a core. The core forming method includes forming one or more mold parts of water-soluble polymer (WSP), each mold part including a bond area and a part forming area, moistening the bond areas, bonding the mold parts together with the bond areas moistened and the part forming areas aligned to form a cavity shaped as a negative of the core, injecting a slurry, which is non-reactive with the WSP, into the cavity and removing the WSP with water once the slurry is cured.

A core forming method is provided for forming a core. The core forming method includes forming one or more mold parts of water-soluble polymer (WSP), each mold part including a bond area and a part forming area, moistening the bond areas, bonding the mold parts together with the bond areas moistened and the part forming areas aligned to form a cavity shaped as a negative of the core, injecting a slurry, which is non-reactive with the WSP, into the cavity and removing the WSP with water once the slurry is cured.

Disclosed herein is a casting core for casting molds, the casting core comprising an inner core and an outer core arranged around the inner core. The outer core contains or consists of ceramic particles bound with a binder. The inner core contains ceramic particles bound with a binder and additionally one or more placeholder elements. The placeholder element(s) is/are at least partially thermally decomposable. Also disclosed is a method for producing the casting core and use of the casting core.

Disclosed herein is a casting core for casting molds, the casting core comprising an inner core and an outer core arranged around the inner core. The outer core contains or consists of ceramic particles bound with a binder. The inner core contains ceramic particles bound with a binder and additionally one or more placeholder elements. The placeholder element(s) is/are at least partially thermally decomposable. Also disclosed is a method for producing the casting core and use of the casting core.

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.

The prevent invention provides a mold core assembly and a slidable element. The mold core assembly is used to form a partial shape of the sliding element applied to a zipper head assembly structure. The mold core assembly includes a first mold core structure and a second mold core structure. The first mold core structure has two first lateral structure bodies and a first middle structure body disposed between the two first lateral structure bodies. The first middle structure body has two first extending portions. The second mold core structure has two second lateral structure bodies and a second middle structure body disposed between the two second lateral structure bodies. The second middle structure body has two second extending portions corresponding to each other. Each first extending portion has a nonuniform thickness, and each second extending portion has a nonuniform thickness.

A disclosed system includes an additive manufacturing printer that performs a layer by layer three-dimensional printing process generating a casting mold based on a three-dimensional numerical specification. The numerical specification is based on a desired casting shape, including internal features such as hollow areas formed by cores, and is further based on a thermo-mechanical model of a casting process. The numerical specification describes variations in material and geometric properties of one or more layers of the casting mold corresponding to variations in the thermal and mechanical properties of the casting processes, as predicted by the thermo-mechanical model. The system may vary the thickness of features of the casting mold, based on predicted cooling rates, to reduce cooling non-uniformities and to provide for controlled, predictable cooling of the casting. The system may further generate trusses and heat sinks in the mold to respectively strengthen and weaken various features of the mold.

A disclosed system includes an additive manufacturing printer that performs a layer by layer three-dimensional printing process generating a casting mold based on a three-dimensional numerical specification. The numerical specification is based on a desired casting shape, including internal features such as hollow areas formed by cores, and is further based on a thermo-mechanical model of a casting process. The numerical specification describes variations in material and geometric properties of one or more layers of the casting mold corresponding to variations in the thermal and mechanical properties of the casting processes, as predicted by the thermo-mechanical model. The system may vary the thickness of features of the casting mold, based on predicted cooling rates, to reduce cooling non-uniformities and to provide for controlled, predictable cooling of the casting. The system may further generate trusses and heat sinks in the mold to respectively strengthen and weaken various features of the mold.

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.