Method and apparatus for production of a cast component

• US 8,082,976 B2
• Filed: 12/06/2007
• Issued: 12/27/2011
• Est. Priority Date: 11/20/1998
• Status: Expired due to Term

• Current Assignee: Rolls-Royce Corporation (Rolls-Royce Holdings Plc)
• Original Assignee: Rolls-Royce Corporation (Rolls-Royce Holdings Plc)
• Inventors: Frasier, Donald J., Schlienger, M. Eric, Brady, Guy Allen, Kush, Matthew T., Vessely, Patrick A.
• Primary Examiner(s): Kerns, Kevin P
• Application Number:
  US11/999,655
• Publication Number:
  US 20080135204A1
• Time in Patent Office: 1,482 Days
• Field of Search: 164/65, 164/66.1, 164/120, 164/122, 164/136, 164/258, 164/335
• US Class Current: 164/335
• 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. A system, comprising:

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 therefore 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 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 includes 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 is positioned within said opening to enable said melt portion to be contacted by molten metal, said cavity has a top and a bottom; and

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.

2. The system of claim 1:

wherein said crucible with molten metal therein is located within said first chamber and said casting mold is located within said second chamber; and

which further includes a pressurized gas source, said source is coupled in fluid communication with said first chamber, and wherein said source is controlled to flow a quantity of pressurized gas into said first chamber and increase the pressure therein to a pressure greater than the pressure in said second chamber, wherein molten metal is discharged from said discharge.

3. The system of claim 1:

wherein said crucible with molten metal therein is located with said first chamber and said casting mold is located within said second chamber; and

which further includes a pressurizing member adapted to increase the pressure on the molten metal within the crucible, at least a portion of said pressurizing member is located within said first chamber and is moveable between a first state wherein molten metal is discharged from said discharge and a second state wherein the flow of molten metal from said discharge is stopped.

4. The system of claim 3, wherein said first state includes moving said pressurizing member into said molten metal.

5. The system of claim 4, wherein said pressurizing member is defined by a bar of the metal material to be melted within said crucible.

6. The system of claim 1, wherein said heat transfer device withdraws sufficient energy to enable the molten metal to be directionally solidified at a rate of about sixty inches per hour.