Innovative Approaches to Produce Narrow, Long and Curved Core Passages in Large Metallic Investment Castings

In the Phase II of this program, work will be focused on producing controlled solidification investment cast (CSIC) articles with net shape, complex, narrow, long, and curved channels within an aluminum alloy article representing military gearbox housing. The program has strict requirements for the materials and techniques used to produce the channel forming core. The produced technical solutions should meet the following objectives: Successfully demonstrate cored passage technology using the investment casting process. Demonstrate investment casting process with representative cored passage design approved by the military and the prime to achieve a Technology Readiness Level of 5. Produce gearbox housing with currently available investment casting tooling utilizing CSIC process with net shaped lubrication core passages. Establish working relationships with end users, investment casting foundries, and channel core producers to enable rapid transition to commercialization in Phase III. The ultimate goal is to transition the technology by investment casting a prototype gear box housing via CSIC process with net shape lubricating channels yielding lower cost and high reliability parts.