System and method for manufacturing railcar coupler headcores

1. A method for manufacturing a railcar coupler, comprising:

providing a first corebox having internal walls defining at least in part perimeter boundaries of at least one rotor core cavity;

at least partially filling the at least one rotor core cavity with a first sand resin, the first sand resin setting after filling to form at least one rotor core;

providing a second corebox, wherein the second corebox comprises an upper mold portion and a lower mold portion having internal walls defining at least in part perimeter boundaries of at least one headcore cavity;

placing the at least one rotor core in the lower mold portion of within the second corebox;

coupling the upper mold portion to the lower mold portion to close the second corebox wherein at least part of the at least one rotor core is not enclosed within the second corebox; and

at least partially filling the at least one headcore cavity with a second sand resin, the second sand resin setting after filling to form at least one headcore, wherein a portion of the at least one headcore encompassing the at least one rotor core has a first parting line which is different from a second parting line of a second portion of the at least one headcore.

2. The method of claim 1 , wherein placing the at least one rotor core within the second corebox comprises positioning the at least one rotor core within a lower portion of the at least one headcore cavity of the second corebox.

3. The method of claim 1 , wherein the second corebox comprises:

the lower mold portion having internal walls defining at least in part perimeter boundaries of a lower portion of the at least one headcore cavity; and

the upper mold portion having internal walls defining at least in part perimeter boundaries of an upper portion of the at least one headcore cavity.

4. The method of claim 3 , further comprising coupling the upper mold portion of the second corebox to the lower mold portion of the second corebox after positioning the at least one rotor core within the second corebox.

5. The method of claim 1 , further comprising inserting a plurality of blow tubes into at least a portion of the second corebox before at least partially filling the at least one headcore cavity with the second sand resin.

6. The method of claim 5 , wherein at least partially filling the at least one headcore cavity with the second sand resin comprises at least partially filling the at least one headcore cavity with the second sand resin via the plurality of blow tubes.

7. The method of claim 1 , wherein the at least one headcore comprises the at least one rotor core.

8. The method of claim 1 , wherein the at least one headcore comprises a plurality of core prints each configured to abut a portion of a coupler cavity of a casting box.

9. The method of claim 1 , further comprising:

providing a casting box having internal walls defining at least in part perimeter boundaries of at least one coupler cavity;

positioning the at least one headcore within the casting box, the at least one headcore configured to form at least one cavity of a coupler;

positioning at least one guard-arm core within the casting box, the at least one guard-arm core configured to form at least one cavity of the coupler;

positioning at least one bottom shelf core within the casting box, the at least one bottom shelf core configured to form at least one cavity of the coupler;

positioning at least one key slot core within the casting box, the at least one key slot core configured to form at least one cavity of the coupler; and

at least partially filling the at least one coupler cavity with a molten alloy, the molten alloy solidifying after filling to form a coupler casting.

10. The method of claim 9 , wherein the bottom shelf core comprises a pin core and a hose lug core.