# US 2014/0150983 A1 · Aerospace sand casting support > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2014/0150983 A1 - Document ID: US20140150983A1 - Status: Published application - Kind: A1 - Application number: 13/706,034 - Filed: 2012-12-05 - Published: 2014-06-05 - Earliest claimed: 2012-12-05 - Assignees: Hamilton Sundstrand Corporation - Inventors: Robert E. Lafurge, JR. - Web page: https://patentgrep.com/patent/US20140150983A1 ## CPC - B22C 21/14: for reinforcing or securing moulding materials or cores, e.g. gaggers, chaplets, pins, bars - B22C 9/00: Moulds or cores (uniquely adapted to particular casting processes B22D); Moulding processes - B22C 9/02: Sand moulds or like moulds for shaped castings - B22C 9/108: {Installation of cores} - B22D 23/00: Casting processes not provided for in groups B22D1/00 - B22D21/00 (making metallic powder by casting B22F9/08; alumino-thermic welding B23K23/00; remelting metals C22B9/16) - B22D 25/00: Special casting characterised by the nature of the product (B22D15/02, B22D17/16, B22D19/00 take precedence; casting stereotype plates B41D3/00) - B22C: FOUNDRY MOULDING (moulding refractory materials in general B28B) - B22D: CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES (shaping of plastics or substances in a plastic state B29C; metallurgical processing, selection of substances to be added to metal C21, C22) ## Abstract A component casting apparatus includes a mold to receive a molten solid for casting a component. The mold includes a first sacrificial layer to define a housing of the component and a second sacrificial layer to form at least one core passage of the component in response to contact from the molten solid. The component casting apparatus further includes a trusset disposed against an outer surface of the second sacrificial layer and formed from metal to support the second sacrificial layer. ## Claims ### Claim 1 A component casting apparatus, comprising: a mold to receive a molten material for casting a component, the mold including a first sacrificial layer to define a housing of the component and a second sacrificial layer to form at least one core passage of the component in response to contact from the molten material, the first and second sacrificial layers defining a metal fusing area between one another to receive the molten material and forms a passage wall of the at least one core passage, the second sacrificial layer being surrounded by the first sacrificial layer and extending along a first direction and having a first diameter to define a hollowed region of the at least one core passage of the component in response to contact from the molten material; and a trusset disposed against an outer surface of the second sacrificial layer without extending through the second sacrificial layer, the trusset formed from metal to support the second sacrificial layer, and including a frame extending in a direction perpendicular to the first direction and disposed between the first and second sacrificial layers, the frame including a first portion in contact with the first sacrificial layer and a second portion in contact with the second sacrificial layer, wherein the second portion includes at least one support surface that extends into the metal fusing area and contacts the second sacrificial layer. ### Claim 2 (depends on 1) The component casting apparatus of claim 1, wherein the trusset is formed from a metal that melts in response to contact from the molten material to form a melted trusset having a homogeneous molecular structure with respect to the molten material to maintain support of the core passage. ### Claim at position 3 3-7. (canceled) ### Claim 8 (depends on 1) The component casting apparatus of claim 1, wherein the frame is a dual-contact frame such that the at least one support surface contacts the second sacrificial layer at two points. ### Claim 9 (depends on 8) The component casting apparatus of claim 8, wherein the at least one support surface is v-shaped having a first contact area that contact the second sacrificial layer a first point and a second contact area different from the first contact area that contacts the second sacrificial layer at a second contact point different from the first contact point. ### Claim 10 (depends on 9) The component casting apparatus of claim 9, wherein the first contact area, the second contact area and the second sacrificial layer define a ventilation region that exhausts gas from the second sacrificial layer. ### Claim 11 (depends on 1) The component casting apparatus of claim 1, wherein the frame is a single-point frame including a support surface having a single contact area that contacts the second sacrificially layer at only a single point. ### Claim 12 (depends on 11) The component casting apparatus of claim 11, wherein the single-point frame has a vent formed therethrough, the vent extending along a center axis of the single-point frame from the second portion to the first portion to exhaust gas from the second sacrificial layer into the first sacrificial layer. ### Claim 13 (depends on 2) The component casting apparatus of claim 2, wherein the trusset and the molten material comprise one of magnesium or aluminum. ### Claim 14 (canceled) ### Claim 15 (depends on 4) The component casting apparatus of claim 4, wherein the first and second sacrificial layers are formed from sand. ### Claim 16 A trusset to support a core structure having radius and length extending perpendicular to the radius, the trusset comprising: a frame extending in a direction perpendicular to the length of the core structure, the frame comprising: an upper portion to contact a first sacrificial layer of a casting apparatus; and a lower portion to contact a second sacrificial layer of the casting apparatus wherein the second sacrificial layer is surrounded by the first sacrificial layer, the second sacrificial layer extending along a first direction and having a first diameter to define a hollowed region of the core structure, wherein the first and second sacrificial layers define a metal fusing area between one another to receive the molten material and form a passage wall of the core structure, the second portion includes at least one support surface that extends into the metal fusing area and contacts the second sacrificial layer, and wherein the trusset includes a frame extending in a direction perpendicular to the first direction and disposed between the first and second sacrificial layers, the frame including a first portion in contact with the first sacrificial layer and a second portion in contact with the second sacrificial layer. ### Claim 17 (depends on 16) The trusset of claim 16, wherein the frame is a dual-contact frame including at least one support surface to contact the core structure at two different points. ### Claim 18 (depends on 16) The trusset of claim 16, wherein the frame is a single-point frame including a support surface having a single contact area to contact the core support at only a single point. ### Claim 19 (depends on 18) The trusset of claim 18, wherein the single-point frame has a vent formed therethrough, the vent extending along a center axis of the single-point frame from the upper portion to the lower portion to exhaust gas from the core structure into the sacrificial layer. ### Claim 20 A method of casting a component including a core passage, the method comprising: forming at least one core structure having a predetermined diameter for defining a hollow region of the core passage; coupling a trusset to an outer surface of the core structure; covering the core structure and the trusset with a molten metal to melt the trusset; solidifying the molten metal and melted trusset to form the core passage such that trusset is integrally formed thereto, wherein the second sacrificial layer is surrounded by the first sacrificial layer, the second sacrificial layer extending along a first direction and having a first diameter to define a hollowed region of the core structure, wherein the first and second sacrificial layers define a metal fusing area between one another to receive the molten material and form a passage wall of the core structure, the second portion includes at least one support surface that extends into the metal fusing area and contacts the second sacrificial layer, and wherein the trusset includes a frame extending in a direction perpendicular to the first direction and disposed between the first and second sacrificial layers, the frame including a first portion in contact with the first sacrificial layer and a second portion in contact with the second sacrificial layer. ### Claim 21 (depends on 20) The method of claim 20, wherein the trusset is formed as a homogeneous molecular structure with respect to an outer surface of the core passage to support the core passage. ### Claim 22 (depends on 21) The method of claim 21, further comprising forming the trusset and the molten metal from the same metal. ### Claim 23 (depends on 9) The component casting apparatus of claim 9, wherein the frame includes a plurality of legs connected to the at least one support surface and separated from each other by a first distance, and wherein the diameter of the second sacrificial layer is less than the first distance.