Method and apparatus for production of a cast component

• US 20080142186A1
• Filed: 12/05/2007
• Published: 06/19/2008
• Est. Priority Date: 11/20/1998
• Status: Abandoned Application

• Current Assignee: Donald J. Frasier, Guy Allen Brady, Matthew T. Kush, Patrick A. Vessely, Schlienger M. Eric
• Original Assignee: Donald J. Frasier, Guy Allen Brady, Matthew T. Kush, Patrick A. Vessely, Schlienger M. Eric
• Inventors: Kush, Matthew T., Vessely, Patrick A., Brady, Guy Allen, Schlienger, M. Eric, Frasier, Donald J.
• Application Number:
  US11/999,484
• Publication Number:
  US 20080142186A1
• Time in Patent Office: Days
• US Class Current: 164/361
• CPC Class Codes: B22D 47/00 Casting plants
• CPC Class Codes: B29C 64/165 using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
• CPC Class Codes: B29C 64/40 Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof
• CPC Class Codes: B33Y 80/00 Products made by additive manufacturing
• CPC Class Codes: C30B 11/00 Single-crystal growth by normal freezing or freezing under temperature gradient, e.g. Bridgman-Stockbarger method C30B13/00, C30B15/00, C30B17/00, C30B19/00 take precedence; under a protective fluid C30B27/00
• CPC Class Codes: C30B 11/002 Crucibles or containers for supporting the melt
• CPC Class Codes: C30B 11/14 characterised by the seed, e.g. its crystallographic orientation
• CPC Class Codes: C30B 29/52 Alloys
• CPC Class Codes: G03F 7/0037 Production of three-dimensional images
• CPC Class Codes: G03F 7/0047 characterised by additives for obtaining a metallic or ceramic pattern, e.g. by firing
• CPC Class Codes: Y10S 117/90 Apparatus characterized by composition or treatment thereof, e.g. surface finish, surface coating
• CPC Class Codes: Y10T 117/10 Apparatus
• CPC Class Codes: Y10T 117/1016 with means for treating single-crystal [e.g., heat treating]

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

Claims

1-80. -80. (canceled)

81. A casting mold, comprising:

a free form fabricated ceramic shell, said ceramic shell having a thin first outer wall defining a cavity therein that is adapted for receiving a molten metal;

a container having a second outer wall with an inner surface, wherein said shell is positioned within said container and spaced from said inner surface; and

at least one support member substantially filling the space between said first outer wall and said inner surface and reinforcing said shell.

82. The casting mold of claim 81, wherein said ceramic shell includes a starter seed receiving inlet.

83. The casting mold of claim 81, wherein said ceramic shell is an integral structure.

84. The casting mold of claim 83, wherein said integral structure is consistent with fabrication by a three-dimensional printing technique.

85. The casting mold of claim 83, wherein said integral structure is consistent with fabrication by a selective laser activation technique.

86. The casting mold of claim 81, wherein said container and said ceramic shell are connected in interference fit.

87. The casting mold of claim 86, wherein said ceramic shell includes a top member portion and a bottom member portion, and where said container defines a tube, and further wherein a portion of said inner surface is in an interference fit with said top member portion and said bottom member portion.

88. The casting mold of claim 87, wherein said container is formed of a material selected from one of a porous ceramic, a ceramic fibermatt and a thermal barrier coated metallic.

92. The casting mold of claim 81, wherein said ceramic shell has a generally airfoil shape portion, and wherein said cavity includes a generally air foil shape.

93. The casting mold of claim 81:

wherein said ceramic shell defines an integral structure having an inlet adapted for receiving a metallic starter seed;

wherein said ceramic shell includes an integral top member and an integral bottom member portion, and wherein a portion of said inner surface is disposed in an interference fit with said top member and said bottom member; and

wherein said at least one support member defines a plurality of ceramic member filling said space between said first outer wall and said inner surface.

94. The casting mold of claim 93, which further includes at least one supplemental heater positioned within said container.

95. The casting mold of claim 81, wherein said ceramic shell is substantially dense.

111. The casting mold of claim 87, wherein said container is formed of a metallic material.

112. The casting mold of claim 93, wherein said container defines a tube.

113. The casting mold of claim 93, wherein said container defines a cup.

89. The casting mold of 81, wherein said at least one support member defines a plurality of support members filling said space between said first outer wall and said inner surface.

90. The casting mold of claim 89, wherein said plurality of support members defined by ceramic media members.

91. The casting mold of claim 90, wherein said plurality of support members has a size within a range of about 0.010 to about 0.100 inches.

96-110. -110. (canceled)

114-169. -169. (canceled)