Patent ID: 8210232

Claim:
A method comprising: placing a first insert and a second insert in a casting mold so that the first insert and second insert are in spaced-apart relationship in the mold, each of the first insert and the second insert comprising a first material; casting a molten second material into the casting mold so that the second material flows between the first insert and the second insert and solidifying the second material to provide a product comprising a cast over body portion with the first insert and second insert, the cast over body portion comprising the second material and so that the second material is mechanically locked or metallurgically bonded to the first material and so that one or both of the first insert and the second insert provides working surface(s), further comprising a plurality of posts extending between and permanently connecting the first insert and the Second insert and wherein the second material surrounds each post and wherein the second material is mechanically locked to the first material at the posts, and wherein the posts extending between and connecting the inserts may be in the shape of round rods, rectangular bars, or curved fins, and wherein the first insert and the second insert and the plurality of posts are a single continuous workpiece, further comprising providing a sectioned annular casting core comprising a plurality of core sections, the core having slots formed therein each with an opened end, placing the core sections between the first insert and the second insert prior to casting, and wherein an associated post is received in the slot through the open end, and after the solidifying, removing the core to provide vanes extending between the first insert and the second insert where the slots in the casting core were and to provide vent channels between the vanes, and wherein a permanent mold and permanent core may be used to cast the second material.