Method and apparatus for production of a cast component

• US 20080169081A1
• Filed: 08/20/2007
• Published: 07/17/2008
• Est. Priority Date: 11/20/1998
• Status: Active Grant

• 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.
• Granted Patent: US 7,779,890 B2
• Time in Patent Office: Days
• US Class Current: 164/258
• 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

1-135. -135. (canceled)

136. A system, comprising:

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.

137. The system of claim 136, which further includes a heater operatively coupled with said starter seed to selectively heat said starter seed.

138. The system of claim 136, wherein said ceramic shell has a thin outer wall, and which further includes a plurality of supporting members within said mold container and abutting said thin outer wall, wherein said plurality of supporting members reinforcing said ceramic shell.

139. The system of claim 138, wherein said ceramic shell and mold container define a casting mold capable of withstanding casting pressures up to about twenty-four inches of nickel.

140. The system of claim 136, which further includes a nozzle coupled to said crucible and in fluid communication with said discharge hole, and wherein said nozzle is positionable in close proximity with said first opening of the ceramic shell.

141. The system of claim 140, wherein said nozzle and said ceramic shell define a structure having a substantially closed passageway therebetween during the passage of molten metal from said dispenser to said ceramic shell.

142. The system of claim 136, wherein the discharge of molten metal from said discharge hole is controlled by a pressure differential.

143. The system of claim 136, wherein said heat transfer passageway includes at least one member that mechanically grips said starter seed, said at least one member is conductively connected with said starter seed.

144. The system of claim 143, wherein said at least one member defines a pair of members that mechanically grip said starter seed.

145. The system of claim 136 wherein said starter seed has a surface adapted for receiving molten metal thereon, and which further includes a means for locating said surface at a predetermined location within said ceramic shell.

146. The system of claim 136:

wherein said ceramic shell and said mold container define a casting mold, said ceramic shell has a thin outer wall, and which further includes a plurality of ceramic members positioned within said mold container and abutting an outer surface of said thin outer wall, and wherein said plurality of supporting members mechanically reinforcing said ceramic shell;

which further includes a nozzle coupled to said crucible and disposed in fluid communication with said discharge hole, and wherein said nozzle is positionable in close proximity with said first opening of the ceramic shell; and

wherein the discharge of molten metal from said discharge hole is controlled by a pressure differential;

wherein said heat transfer pathway is formed in a pair of conductive members that mechanically grip said starter seed; and

wherein said starter seed has a surface adapted for receiving molten metal thereon, and which further includes at least one locating member contacting said starter seed to position said surface at a predetermined location within said ceramic shell.

170. The system of claim 136, wherein said ceramic shell is formed by a stereolithography process.

171. The system of claim 146, wherein said ceramic shell is formed in a process including the photopolymerization of a ceramic filled resin.

147. 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 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.

148. The system of claim 147:

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.

149. The system of claim 147:

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 discharge from said discharge and a second state wherein the flow of molten metal from said discharge is stopped.

150. The system of claim 149, wherein said first state includes moving said pressurizing member into said molten metal.

151. The system of claim 150, wherein said pressurizing member is defined by a bar of the metal material to be melted within said crucible.

152. The system of claim 147, wherein said heat transfer device withdrawing sufficient energy to enable the molten metal to be directionally solidified at a rate of about sixty inches hour.

155. The apparatus of claim 147, wherein said ceramic shell was formed by a selective laser activation technique.

156. The apparatus of claim 147, wherein said ceramic shell was formed by a three-dimensional printing technique.

157. The apparatus of claim 147, which further includes a meltable member positioned within said ceramic shell and contactable by said molten metal passing from said molten metal discharge to said cavity, whereby the molten metal melts said meltable member and mixes with the molten metal in said cavity.

172. The system of claim 155, wherein said selective laser activation technique defines a stereolithography process.

173. The system of claim 148, wherein said ceramic shell is formed by a stereolithography process.

153. (canceled)

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.

158-169. -169. (canceled)

174. A system comprising:

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.

175. The system of claim 174, which further includes a heater operatively coupled with said starter seed to selectively heat said starter seed.

176. The system of claim 174, wherein said ceramic shell has a thin outer wall.

177. The system of claim 174, which further includes a nozzle coupled to said crucible and in fluid communication with said discharge hole, and wherein said nozzle is positionable in close proximity with said first opening of the ceramic shell.

178. The system of claim 177, wherein said nozzle and said ceramic shell define a structure having a substantially closed passageway therebetween during the passage of molten metal from said dispenser to said ceramic shell.

179. The system of claim 174, wherein the discharge of molten metal from said discharge hole is controlled by a pressure differential.

180. The system of claim 174, wherein said heat transfer passageway includes at least one member that mechanically grips said started seed, said at least one member is conductively connected with said starter seed.

181. The system of claim 180, wherein said at least one member defines a pair of members that mechanically grip said starter seed.

182. The system of claim 174, wherein said starter seed has a surface adapted for receiving molten metal thereon, and which further includes a means for locating said surface at a predetermined location within said ceramic shell.

183. The system of claim 174:

wherein said ceramic shell has a thin outer wall;

which further includes a nozzle coupled to said crucible and disposed in fluid communication with said discharge hole, and wherein said nozzle is positionable in close proximity with said first opening of the ceramic shell;

wherein the discharge of molten metal from said discharge hole is controlled by a pressure differential;

wherein said heat transfer pathway is formed in a pair of conductive members that mechanically grip said starter seed; and

wherein said starter seed has a surface adapted for receiving molten metal thereon, and which further includes at least one locating member contacting said starter seed to position said surface at a predetermined location within said ceramic shell.

184. A system, comprising:

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.

185. The system of claim 184:

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 great than the pressure in said second chamber, wherein molten metal is discharged from said discharge.

186. The system of claim 184:

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 discharge from said discharge and a second state wherein the flow of molten metal from said discharge is stopped.

187. The system of claim 186, wherein said first state includes moving said pressurizing member into said molten metal.

188. The system of claim 187, wherein said pressurizing member is defined by a bar of the metal material to be melted within said crucible.

189. The system of claim 184, wherein said heat transfer device withdrawing sufficient energy to enable the molten metal to be directionally solidified at a rate of about sixty inches hour.

191. The apparatus of claim 184, which further includes a meltable member positioned within said ceramic shell and contactable by said molten metal passing from said molten metal discharge to said cavity, whereby the molten metal melts said meltable member and mixes with the molten metal in said cavity.

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.