Mold compositions for additive casting of metal objects
AssigneeMagnus Metal Ltd.
InventorsRoi Levi, Orel Birodker, Valeriya Frid Zaid, Hana Arini Yadid, Moshe Frenkel, Hani Farran
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Abstract
The disclosure concerns printable refractory compositions, more particularly ceramic-based pastes for 3D printing of molds for additive metal casting. In particular, the present disclosure concerns composition for forming mold regions having controlled thermal conductivity and dissipation and controlled release of gaseous products therefrom during heating to mitigate mechanical failure risks in an additive casting process of metal objects.
Claims20
A paste composition for manufacturing of a mold for additive casting of a metal object, in a process of subsequent formation of production layers, each production layer comprising at least one mold region and at least one metal object region, the mold region comprising at least one paste composition, the paste composition comprising:
- between about 65 wt % and about 75 wt % of at least one ceramic material in particulate form;
- between about 3 wt % and about 8 wt % of at least one inorganic binder, wherein said at least one inorganic binder is different from said at least one ceramic material;
- between about 4 wt % and about 14 wt % of at least one porosity controlling additive;
- between about 0.05 wt % and about 3 wt % of at least one of an energy absorbing additive and an energy conductive additive, wherein said energy absorbing additive is different from said at least one ceramic additive and said energy conductive additive is different from said at least one ceramic material, and wherein said energy absorbing additive is different from said energy conductive additive;
- and
- between about 10 wt % and about 20 wt % of at least one carrier liquid;
- the paste composition having a mass loss of at least about 10 wt % out of the total mass of the paste composition when heated to about 220° C. for a period of time of no more than about 30 minutes;
- wherein said at least one ceramic material comprises a mixture of at least one first ceramic material having a particle size of between about 50 μm and about 300 μm and at least one second ceramic material having a particle size of between about 1 μm and about 15 μm.
A paste composition for manufacturing of a mold for additive casting of a metal object, in a process of subsequent formation of production layers, each production layer comprising at least one mold region and at least one metal object region, the mold region comprising at least one paste composition, the paste composition comprising:
- between about 65 wt % and about 75 wt % of at least one ceramic material in particulate form;
- between about 3 wt % and about 8 wt % of at least one inorganic binder, wherein said inorganic binder being different from said at least one ceramic material;
- between about 4 wt % and about 14 wt % of at least one porosity controlling additive in the form of microspheres, said microspheres being made of aluminum oxide, aluminum silicate, silicon dioxide, borosilicate glass, yttria-stabilized zirconia, or mixtures thereof;
- between about 0.05 wt % and about 3 wt % of at least one of an energy absorbing additive and an energy conductive additive, wherein said energy absorbing additive is different from said at least one ceramic additive and said energy conductive additive is different from said at least one ceramic material, and wherein said energy absorbing additive is different from said energy conductive additive;
- and
- between about 10 wt % and about 20 wt % of at least one carrier liquid;
- wherein the paste composition has a mass loss of at least about 10 wt % out of the total mass of the paste composition when heated to about 220° C. for a period of time of no more than about 30 minutes.
Dependencies are inferred from the claim text.