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1. (WO1979000298) INSULATED MANIFOLD WITH DOUBLE CAST WALLS AND METHOD OF MAKING
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Claims

1. A method of forming a composite article
(10) having an inner cast meta_l portion (11) , an outer cast metal portion (12) , and an intermediate insulating portion (13) , comprising the steps of:
forming an expendable gasifiable pattern (16) of said inner portion;
forming an expendable gasifiable pattern (17) of said outer portion; assembling said inner and outer portions with an insulative portion (13) therebetween;
forming a mold (32) about the assembled patterns;
pouring molten casting metal (27) into said mold to gasify said patterns in said mold and form said inner and outer cast metal portions (11,12) inwardly and outwardly of said insulative portion (13) respectively.

2. The method of forming a composite article of Claim 1 wherein said inner portion (11) is cast of a metal different from that of said outer portion (12) .

• 3. The method of forming a composite article of Claim 1 wherein said metal portions (11, 12) are cast sequentially.

4. The method of forming a composite article of Claim 1 wherein said cast portions (ll, 12) are cast concurrently.

5. The method of forming a composite article of Claim 1 wherein each of said patterns (16,17) includes sprue, gating, and vent passage portions (23) .

6. The method of forming a composite article of Claim 1 wherein each of said patterns (16,17) is formed of a plurality of sections .

7. The method of forming a composite article of Claim 1 wherein said insulative portion (13) is preformed and installed in association with one of said patterns (16,17) prior to the assembly of the other pattern therewith.

8. The method of forming a composite article of Claim 1 wherein said insulative portion (13) is provided about said inner pattern (16) prior to the
assembly of said outer pattern (17) thereabout.

9. The method of forming a composite article of Claim 1 wherein said insulative portion (13) is pro-vided in a plurality of sections about said inner pattern (16) prior to the assembly of said outer pattern (17) thereabout.

10. The method of forming a composite article of Claim 1 wherein a source of molten casting metal (27) is provided and delivered to said patterns (16,17) along separate paths (25,26) said method including the step of introducing material into the metal (27) being delivered to one of said patterns to cause the cast portion formed thereby to have different metallurgical characteristics from those of the metal forming the outer cast portion.

11. The method of forming a. composite article of Claim 1 wherein said assembled patterns (16,17) are provided with an outer refractory coating.

12. The method of forming a composite article of Claim 1 wherein said mold (32) is formed of flow-able particulate material.
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13. The method of forming a composite article of Claim 1 wherein said mold is formed of flowable particulatematerial, said method including the step of vibrating the mold (32) about the assembled patterns

(16,17).

14. The method of forming a composite article of Claim 1 wherein said patterns (16,17) are formed of § a plurality of sections adhesively joined.

15. The method of forming a composite article of Claim 1 wherein said insulative portion (13) comprises a plurality of preformed sections adhesively joined.

. 16. A composite article (10) comprising:
an inner casting (11)
an outer casting; (12) and
an insulative portion (13) defining the pattern (16) for the outer surface (14) of the inner casting (11) and the pattern (17) for the inner surface of the outer casting (12) , said insulative portion (13) being captured between said castings (11,12) to define a thermal barrier therebetween.

17. The composite article of Claim 16 wherein said castings (11,12) are formed of metal (27)..

18. The composite article of Claim 16 wherein said castings (11,12) are formed of different materials.

19. The composite article of Claim 16 wherein said castings (11,12) are formed of different metallic materials.

20. The composite article of Claim 16 wherein said castings (11,12) and insulative portion (13) are interlocked together.