Castings of metallic alloys with improved surface quality, structural integrity and mechanical properties fabricated in finegrained isotropic graphite molds under vacuum
First Claim
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1. A method of making cast shapes of a metallic alloy, comprising the steps of:
- melting the alloy under vacuum or partial pressure of inert gas;
pouring the alloy into a mold with a cavity, wherein the mold is made of machined graphite, wherein the graphite has been isostatically or vibrationally molded and has ultra fine isotropic grains having a particle size in the range of 3 to 40 microns, a density between 1.65 and 1.9 grams/cc, flexural strength between 5,500 and 20,000 psi, compressive strength between 9,000 and 35,000 psi, and porosity below 15%;
solidifying the melted alloy into a solid body taking the shape of the mold cavity.
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Abstract
Methods for making various metallic alloys such as nickel, cobalt and/or iron based superalloys, stainless steel alloys, titanium alloys and titanium aluminide alloys into engineering components by melting of the alloys in a vacuum or under a low partial pressure of inert gas and subsequent casting of the melt in the graphite molds under vacuum or low partial pressure of inert gas are provided, the molds having been fabricated by machining high density, high strength ultrafine grained isotropic graphite, wherein the graphite has been made by isostatic pressing or vibrational molding.
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Citations
22 Claims
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1. A method of making cast shapes of a metallic alloy, comprising the steps of:
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melting the alloy under vacuum or partial pressure of inert gas;
pouring the alloy into a mold with a cavity, wherein the mold is made of machined graphite, wherein the graphite has been isostatically or vibrationally molded and has ultra fine isotropic grains having a particle size in the range of 3 to 40 microns, a density between 1.65 and 1.9 grams/cc, flexural strength between 5,500 and 20,000 psi, compressive strength between 9,000 and 35,000 psi, and porosity below 15%;
solidifying the melted alloy into a solid body taking the shape of the mold cavity. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22)
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Specification