Method of producing unitary multi-element ceramic casting cores and integral core/shell system
First Claim
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1. A method of fabricating a unitary, multi-element ceramic article comprising:
- a) preparing multiple disposable tool elements configured to be joined together to define multiple cavities that mirror the geometry of the unitary multi-element ceramic article;
b) joining the disposable tool elements together to form multiple cavities;
c) filling the cavities with a ceramic slurry having a liquid carrier;
d) solidifying the ceramic slurry;
e) removing the disposable tool elements.
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Abstract
A method for producing ceramic articles having a complex geometry. Temporary tooling is provided having cavities corresponding in shape to the desired ceramic article. The cavities are filled with a ceramic slurry which is solidified by freezing or gelation of a polymer. The ceramic is treated to remove the original liquid portion of the slurry and the temporary tooling is removed. The ceramic is then sintered. The ceramic article thus obtained may be used to investment cast a metal article.
40 Citations
21 Claims
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1. A method of fabricating a unitary, multi-element ceramic article comprising:
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a) preparing multiple disposable tool elements configured to be joined together to define multiple cavities that mirror the geometry of the unitary multi-element ceramic article;
b) joining the disposable tool elements together to form multiple cavities;
c) filling the cavities with a ceramic slurry having a liquid carrier;
d) solidifying the ceramic slurry;
e) removing the disposable tool elements. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16)
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17. A disposable mold assembly for producing unitary multiple element ceramic articles comprising:
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a plurality of disposable tool elements; and
at least one interlocking feature located on each of the disposable tool elements, wherein the plurality of disposable tool elements are configured to connect via the interlocking features to form a multi cavity mold. - View Dependent Claims (18, 19, 20)
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21. A system for fabricating a unitary, multi-element ceramic article comprising:
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a plurality of multiple disposable tool elements configured to be joined together to define multiple cavities that mirror the geometry of the unitary multi-element ceramic article;
a joining structure configured to couple the disposable tool elements together to form multiple cavities;
a ceramic slurry having a liquid carrier filling the form cavities;
a means for solidifying the ceramic slurry; and
a means for removing the disposable tool elements.
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Specification