Method and apparatus for production of a cast component
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Accused Products
Abstract
A system for producing cast components from molten metal. One form of the present invention includes a system for the precision pouring of molten metal within a casting mold. The precision pouring system is driven by a pressure differential.
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Citations
159 Claims
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1-146. -146. (canceled)
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147. A system, comprising:
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a crucible adapted for holding a metal material; a mechanical housing having a first chamber and a second chamber, said crucible located within said first chamber; a heater located within said first chamber to heat the metal material within said crucible to a molten metal state; a metallic starter seed having a body member including a melt portion; a pressure controlled molten metal delivery system positioned within said crucible, said molten metal delivery system including a member with a passageway therethrough for the passage of molten metal, said passageway having a first portion adapted to receive molten metal therein from beneath the surface of the molten metal within the crucible and a second portion defining a molten metal discharge; a casting mold including a free form thin ceramic shell located within and outer mold container, said casting mold includes at least one reinforcement member between said ceramic shell and said outer mold container for supporting said ceramic shell, wherein said ceramic shell including a cavity to receive the molten metal material discharged from said molten metal discharge and an opening to receive the metallic starter seed, wherein said melt portion positioned within said opening to enable said melt portion to be contacted by molten metal, said cavity has a top and a bottom; a heat transfer device mechanically connected with said starter seed for removing heat from the starter seed to cause directional solidification from said bottom to said top of the metal material within said cavity. - View Dependent Claims (148, 149, 150, 151, 152)
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153. A system for casting a product, comprising:
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a vacuum furnace having a first chamber and a second chamber; a crucible positioned within said first chamber, said crucible has a discharge hole; a heater positioned within said first chamber adjacent said crucible and adapted for heating the metal material to a molten metal state; an integral free form ceramic casting shell having a molten metal receiving cavity therein and a starter seed receiving portion, said ceramic casting shell positioned within a shell container and reinforced by a plurality of reinforcing members located within said shell container and at least a portion abutting said ceramic shell; dispensing means located within said crucible for discharging molten metal into said ceramic casting shell; a metallic starter seed having a melt portion, at least a portion of said starter seed positioned within said starter seed receiving portion of said ceramic shell, said melt portion oriented to receive molten metal thereon from said dispensing means; and directional solidification means coupled with said starter seed for directionally solidifying the molten metal within said casting shell. - View Dependent Claims (155, 156, 157, 158)
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154. The apparatus of 153, which further includes a seed heater operatively coupled with metallic starter seed to adjust the temperature of said starter seed.
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159-169. -169. (canceled)
Specification