Mold assembly for use in a liquid metal cooled directional solidification furnace

A liquid metal cooled directional solidification furnace comprising:

• a heating portion including a heating chamber having a first temperature;
• a cooling portion including a cooling chamber provided with liquid metal having a second temperature, the second temperature being less than the first temperature;
• and
• a mold assembly positioned in each of the heating portion and cooling portion, the mold assembly including:
• a mold member having a main body portion that defines an interior mold cavity, the mold member being positioned in the heating chamber;
• and
• a chill-plate formed from a material having a thermal diffusivity at 600° K greater than approximately 10 E-6 m2/s and at least partially immersed in the liquid metal, the chill-plate including a main body portion having a first extending to a second surface through an intermediate portion, wherein the chill-plate, partially immersed in the liquid metal, establishes a thermal gradient between the mold member and the heating chamber.

A method of forming a cast component in a liquid metal cooled directional solidification furnace comprising:

• supporting a portion of a mold assembly upon a chill-plate formed from a material having a thermal diffusivity at 600° K greater than approximately 10 E-6 m2/s into a liquid cooled directional solidification furnace;
• positioning a the mold member in a heating chamber having a first temperature and a portion of the chill-plate into a liquid metal bath having a second temperature, the second temperature being higher than the first temperature;
• raising the temperature in the heating chamber from the first temperature to a third temperature, the third temperature being substantially higher than the second temperature;
• and
• maintaining the portion of the mold member supported upon the chill-plate at a fourth temperature, the fourth temperature being substantially less than the third temperature.