Method and apparatus for production of a cast component

• US 8,844,607 B2
• Filed: 12/05/2007
• Issued: 09/30/2014
• Est. Priority Date: 11/20/1998
• Status: Expired due to Fees

• Current Assignee: Rolls-Royce Corporation (Rolls-Royce Holdings Plc)
• Original Assignee: Rolls-Royce Corporation (Rolls-Royce Holdings Plc)
• Inventors: Frasier, Donald J., Brady, Guy Allen, Kush, Matthew T., Vessely, Patrick A.
• Primary Examiner(s): Kerns, Kevin P
• Application Number:
  US11/999,480
• Publication Number:
  US 20080149295A1
• Time in Patent Office: 2,491 Days
• Field of Search: 164/361, 164/338.1, 164/122.1, 164/122.2, 164/516, 164/256, 164/258, 164/335, 164/369
• 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. A casting mold, comprising:

a refractory member having a first outer wall with an inner surface;

a contiguous multi-wall ceramic shell that is not constructed of a plurality of separate components and thus having an absence of interfaces between separate components, the contiguous multi-wall shell also having a second outer wall with a thickness less than about 0.040 inches and a molten metal receiving cavity therein, said contiguous multi-wall ceramic shell includes a starter seed receiving inlet portion opening into said molten metal receiving cavity, and wherein said contiguous multi-wall ceramic shell is positioned within said refractory member; and

at least one support member positioned within said refractory member between said first outer wall and said second outer wall to abut and reinforce said second outer wall.

2. The casting mold of claim 1, wherein said refractory member and said contiguous multi-wall ceramic shell are coupled in interference fit.

3. The casting mold of claim 2, wherein said at least one support member defines a plurality of support members positioned within said refractory member.

4. The casting mold of claim 3, where said plurality of support members are not fixed to either of said outer walls.

5. The casting mold of claim 1, wherein said refractory member is a thick walled fibrous ceramic member with an interior cavity, and wherein said at least one support member defines a plurality of ceramic members filling the space between said second outer wall and said inner surface.

7. The casting mold of claim 1, wherein said contiguous multi-wall ceramic shell has a first portion with a first density and a second portion with a second density, and wherein said first density is greater than said second density.

8. The casting mold of claim 1, which further includes a mold heater positioned within said refractory member.

9. The casting mold of claim 1, wherein said contiguous multi-wall ceramic shell is substantially dense.

10. The casting mold of claim 1, wherein said contiguous multi-wall ceramic shell and said at least one support member defines a structure that can withstand a casting head pressure of about three to about twenty-four inches of nickel.

11. The casting mold of claim 1, where said refractory member defines a container.

12. The casting mold of claim 11, when said container and said contiguous multi-wall ceramic shell are disposed in interference fit.

13. The casting mold of claim 11, wherein said contiguous multi-wall ceramic shell has a first portion with a first density and a second portion with a second density, and wherein said first density is greater than said second density.

14. The casting mold of claim 13, wherein said refractory member is a thick walled fibrous ceramic member with an interior cavity, and wherein said at least one support member defines a plurality of contiguous multi-wall ceramic members filling the space between said second outer wall and said inner surface.

15. The casting mold of claim 5, wherein said contiguous multi-wall ceramic shell has a first portion with a first density and a second portion with a second density, and wherein said first density is greater than said second density.

6. A casting mold, comprising:

a refractory member forming a container having a first outer wall with an inner surface;

a contiguous multi-wall ceramic shell having a second outer wall and a molten metal receiving cavity therein, said contiguous multi-wall ceramic shell includes a starter seed receiving inlet portion opening into said molten metal receiving cavity, said molten metal cavity and said second outer wall define at least a portion of the shape of a cast component,

and wherein said contiguous multi-wall ceramic shell is positioned within said refractory member; and

at least one support member positioned within said refractory member between said first outer wall and said second outer wall to abut and reinforce said second outer wall.

16. The casting mold of claim 6, wherein said at least one support member defines a plurality of support members along said second outer wall.

17. The casting mold of claim 6, wherein said refractory member and said contiguous multi-wall ceramic shell are coupled in interference fit.

18. The casting mold of claim 6, wherein said contiguous multi-wall ceramic shell has a first portion with a first density and a second portion with a second density, and wherein said first density is greater than said second density.

19. The casting mold of claim 6, wherein said contiguous multi-wall ceramic shell is substantially dense.

20. A casting mold, comprising:

a refractory member having a first outer wall with an inner surface;

a free-form fabricated multi-wall ceramic shell that is constructed as a contiguous piece and not from coupling separate components, the free-form fabricated multi-wall ceramic shell having a second outer wall with a thickness less than about 0.040 inches and a molten metal receiving cavity therein, said shell includes a starter seed receiving inlet portion opening into said molten metal receiving cavity, and wherein said shell is positioned within said refractory member; and

means for reinforcing the second outer wall when molten metal is poured in the molten metal receiving cavity, the means positioned between the first outer wall and the second outer wall.

21. A casting mold, comprising:

a refractory member having a first outer wall with an inner surface;

a contiguous multi-wall ceramic shell that is wholly constructed as a single article and not from a construction of multiple pieces coupled together, the contiguous multi-wall ceramic shell having a second outer wall with a thickness less than about 0.040 inches and a molten metal receiving cavity therein, said contiguous multi-wall ceramic shell includes a starter seed receiving inlet portion opening into said molten metal receiving cavity, and wherein said contiguous multi-wall ceramic shell is positioned within said refractory member; and

a plurality of particulate reinforcing members disposed to support the second outer wall when molten metal is poured in the molten metal receiving cavity, the particulate reinforcing members positioned between the first outer wall and the second outer wall.