Patent ID: 7506705

Claim:
A cast article comprising at least one insert molded element produced by the method of: placing at least a first portion of at least one carbide insert element adjacent an interior surface portion of a mold having an interior shape substantially complementary to the exterior shape of the article, said carbide insert element defining an engaging surface between the first portion and a second portion, said carbide insert element being at least partially coated with a metal coating prior to being placed adjacent the interior surface of the mold; introducing a dissolvable foam material in a relatively pourable state into the mold so as to at least partially fill the mold and at least partially surround the second portion of the at least one insert element with the foam material; permitting the foam material to transform from the relatively pourable state to a relatively solid state comprising a monolithic molded structure of the same size and shape as the cast article and having at least one element insert molded therein; placing a composite of the at least one element and the molded structure in an enclosure of larger volume than said composite and substantially filling the volume between the composite and the interior of the enclosure with a heat resistant casting media; communicating a molten material into the casting media and thereby dissolving the molded structure in a manner such that the molten material flows into engagement with the second portion of the at least one element and occupies the volume and assumes the shape of the foam material, said second portion of the at least one element engages with molten material by means of a cross lobe on said second portion of the at least one element, wherein said second portion is completely surrounded by said molten material, and said first portion remains exposed; permitting the molten material to solidify and thereby form the cast article having at least one element insert molded therein; and separating the casting media from the cast article and the at least one element.