Synthetic model casting
First Claim
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1. A casting method comprising:
- creating a 3-D numerical model of a hollow component having an external wall;
creating a synthetic model of said component from said numerical model having a corresponding synthetic external wall;
casting a core inside said synthetic model; and
removing said synthetic model from said core.
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Abstract
A synthetic model of a component is created from a 3-D numerical model thereof. A core is then cast inside the synthetic model. The synthetic model may then be removed from the cast core, and then the cast core is used for casting an authentic component therearound. The core is removed from inside the authentic component, which authentic component precisely matches the original synthetic model therefor.
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Citations
32 Claims
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1. A casting method comprising:
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creating a 3-D numerical model of a hollow component having an external wall;
creating a synthetic model of said component from said numerical model having a corresponding synthetic external wall;
casting a core inside said synthetic model; and
removing said synthetic model from said core. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10)
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11. A casting method comprising:
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creating a 3-D numerical model of a hollow component having an external wall;
creating a synthetic model of said component from said numerical model having a corresponding synthetic external wall;
casting a core inside said synthetic model;
removing said synthetic model from said core;
casting an authentic component around said core; and
removing said core from inside said authentic component. - View Dependent Claims (12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26)
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27. A casting method comprising:
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creating a 3-D numerical model of a hollow turbine airfoil having an external sidewall;
creating a monolithic synthetic model of said airfoil from said numerical model by depositing material in 3-D space over the boundary of said numerical model, and including a corresponding synthetic external wall;
casting a core inside said synthetic model;
removing said synthetic model from said core;
casting an authentic turbine blade around said core; and
removing said core from inside said authentic blade. - View Dependent Claims (28, 29, 30)
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31. A method for making a casting core for a hollow component, comprising:
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manufacturing a single-piece sacrificial die using an additive layer manufacturing method, said die comprising an external wall and at least one internal cavity matching corresponding features of said component;
introducing a ceramic slurry into said cavity of said die, said slurry comprising a ceramic and a carrier fluid;
curing said slurry to form a monolithic ceramic casting core; and
removing said sacrificial die by exposing said die to an environment adapted to destroy said die while leaving said ceramic casting core intact.
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32. A method for making a hollow component having an external wall, said method comprising:
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providing a single-piece sacrificial die, said die comprising an external wall corresponding with said component external wall, and at least one internal cavity;
introducing a ceramic slurry into said at least one cavity of said die, said slurry comprising a ceramic and a carrier fluid;
curing said slurry to form a monolithic ceramic casting core;
removing said sacrificial die by exposing said die to an environment adapted to destroy said die while leaving said ceramic casting core intact; and
performing an investment casting process using said ceramic casting core as part of a mold-core assembly to form said component.
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Specification