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
191 Claims
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1-135. -135. (canceled)
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136. A system, comprising:
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a vacuum furnace; a crucible positioned within said vacuum furnace and having a discharge hole; a heater positioned within said vacuum furnace for melting the metal material within said crucible; a metallic starter seed; a dispenser located within said crucible and around said discharge hole, said dispenser has an outer portion with at least one entrance for the passage of molten metal from said crucible and an exit spaced from said at least one entrance for the passage of molten metal to an inner reservoir, and wherein said inner reservoir receives molten metal from said outer portion until said inner reservoir reaches a full state, and at said full state the flow of molten metal to said inner reservoir is stopped and the molten metal within said inner reservoir is discharged through said discharge hole; an integral free form fabricated ceramic shell having a first opening for receiving the molten metal discharged through said discharge hole and a second opening for receiving said starter seed, said ceramic shell positioned within and connected with a mold container; and a heat transfer pathway mechanically connected with said starter seed for the removal of heat from said starter seed, said heat transfer pathway remains mechanically connected with said starter seed as the molten metal within said ceramic shell is directionally solidified. - View Dependent Claims (137, 138, 139, 140, 141, 142, 143, 144, 145, 146, 170, 171)
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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 an 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, 155, 156, 157, 172, 173)
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153. (canceled)
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154. The apparatus of 147, which further includes a seed heater operatively coupled with metallic starter seed to adjust the temperature of said starter seed.
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158-169. -169. (canceled)
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174. A system comprising:
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a vacuum furnace; a crucible positioned within said vacuum furnace and having a discharge hold;
a heater positioned within said vacuum furnace for melting the metal material within said crucible;a metallic starter seed; a dispenser located within said crucible and around said discharge hole, said dispenser has an outer portion with at least one entrance for the passage of molten metal from said crucible and an exit spaced from said at least one entrance for the passage of molten metal to an inner reservoir, and wherein said inner reservoir receives molten metal from said outer portion until said inner reservoir reaches a full state, and at said full state the flow of molten metal to said inner reservoir is stopped and the molten metal within said inner reservoir is discharged through said discharge hole; an integral free form fabricated ceramic shell having a first opening for receiving the molten metal discharged through said discharge hole and a second opening for receiving said starter seed; and a heat transfer pathway mechanically connected with said starter seed for the removal of heat from said starter seed, said heat transfer pathway remains mechanically connected with said starter seed as the molten metal within said ceramic shell is directionally solidified. - View Dependent Claims (175, 176, 177, 178, 179, 180, 181, 182, 183)
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184. A system, comprising:
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a crucible adapted for holding a metal material; a mechanical housing having a first chamber and 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 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 (185, 186, 187, 188, 189, 191)
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190. The apparatus of 184, which further includes a seed heater operatively coupled with said metallic starter seed to adjust the temperature of said starter seed.
Specification