US 11,813,669 B2Granted

Method for making an integrated core-shell structure

AssigneeGeneral Electric Company

InventorsJames Herbert Deines, Brian David Przeslawski, Michael John McCarren, Gregory Terrence Garay, Douglas Gerard Konitzer, Mark Willard Marusko, Xi Yang, Brian Patrick Peterson

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Abstract

Partial integrated core-shell investment casting molds that can be assembled into complete molds are provided herein. Each section of the partial mold may contain both a portion of a core and portion of a shell. Each section can then be assembled into a mold for casting of a metal part. The partial integrated core-shell investment casting molds and the complete molds may be provided with filament structures corresponding to cooling hole patterns on the surface of the turbine blade or the stator vane, which provides a leaching pathway for the core portion after metal casting. Core filaments that can be used to supplement the leaching pathway, for example in a core tip portion of the mold are also provided herein.

Claims20

Dependent claims

A method for fabricating a ceramic mold, comprising:

(a) contacting a cured portion of a workpiece with a liquid ceramic photopolymer;
(b) irradiating a portion of the liquid ceramic photopolymer adjacent to the cured portion through a window contacting the liquid ceramic photopolymer to form a polymerized material;
(c) removing the workpiece from the liquid ceramic photopolymer that remains uncured;
and
(d) repeating steps (a)-(c) until a monolithic ceramic mold is formed from the polymerized material, wherein the monolithic ceramic mold comprises a core portion, a shell portion, at least one filament spanning between and monolithically joining the core portion and the shell portion, and at least one cavity between the core portion and the shell portion, wherein the at least one cavity is adapted to define a shape of a cast component and the at least one filament is adapted to define a hole in the cast component upon casting and removal of the ceramic mold.

2 more elements

Dependencies are inferred from the claim text.

Facts

Application: 17/826,742Filed 27 May 2022 · division
Priority: 13 Dec 2016
Published: US 2022/0288673 A115 Sep 2022
Granted: 14 Nov 2023
Term ends: Not estimatedThe source records don’t support an estimate.

Classification38 codes

B22D 25/02
Special casting characterised by the nature of the product: by its peculiarity of shape; of works of art
B22C 1/22
Of organic agents: of resins or rosins
B22C 9/02
Moulds or cores ; Moulding processes: sand moulds or like moulds for shaped castings
B22C 9/10
Moulds or cores ; Moulding processes: cores; Manufacture or installation of cores

Family

Application15/377,711Parent of this continuation · filed 13 Dec 2016
Application15/377,673Parent of this continuation · filed 13 Dec 2016
Application15/377,728Parent of this continuation · filed 13 Dec 2016
Application15/377,783Parent of this continuation · filed 13 Dec 2016
Application15/377,746Parent of this continuation · filed 13 Dec 2016
Application15/377,766Parent of this continuation · filed 13 Dec 2016
Application15/377,796Parent of this continuation · filed 13 Dec 2016
Application15/377,759Parent of this continuation · filed 13 Dec 2016
Application15/377,787Parent of this continuation · filed 13 Dec 2016
Application16/827,117Parent of this division · filed 23 Mar 2020
US 2022/0288673 A1Pre-grant publication · published 15 Sep 2022
US 11,351,599 B2Parent of this division
Application16/827,117Parent of this continuation
US 10,807,154 B2Parent of this continuation
US 2018/0161852 A1Published application
US 2018/0161853 A1Published application
US 2018/0161854 A1Published application
US 2018/0161855 A1Published application
US 2018/0161856 A1Published application
US 2018/0161857 A1Published application
US 2018/0161858 A1Published application
US 2018/0161859 A1Published application
US 2018/0161866 A1Published application
US 2020/0222978 A1Published application
US 11,813,669 B2This patent

From the US filing history. Foreign family members aren’t listed.