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US 2009/0014623 A1Published application
Electrophoretic Casting
OwnerDouglas M. Matson, Rakesh Venkatesh +2inventors
InventorsDouglas M. Matson, Rakesh Venkatesh, John MacChesney, Thomas Stockert
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Abstract
Methods for electrophoretic deposition of molds for casting processes are provided. Electrophoresis is used to deposit very fine particles on a template from a slurry comprising an ionic dispersion agent. The resulting green shell is then dried and sintered to form a mold.
Claims78
A method of forming a shell on a template, comprising:
- immersing the template in a slurry, the slurry comprising
- a plurality of colloidal particles;
- and
- a sufficient quantity of salt to impart an effective charge to the colloidal particles;
- applying a voltage to the template, thereby causing the charged colloidal particles to be deposited on the template to form a green shell;
- and
- sintering the green shell to form a solidified shell having greater mechanical integrity than the green shell.
4 more elements
A method of producing a desired article, comprising:
- providing a template having a predetermined shape;
- depositing an investment mold on the template, wherein depositing comprises:
- immersing the template in a slurry, the slurry comprising a plurality of colloidal particles and a sufficient quantity of salt to impart an effective charge to the colloidal particles;
- applying a voltage to the template, thereby causing the charged colloidal particles to be deposited on the template to form a green shell;
- and
- sintering the green shell to form the investment mold;
- removing the template;
- and
- casting the desired article in the investment mold.
6 more elements
A method of producing a desired article by investment casting, comprising:
- providing a master template having a predetermined shape;
- using the master template to produce a transfer mold having a shape complementary to the master template, wherein the transfer mold comprises a flexible material;
- molding a sacrificial template in the transfer mold, the sacrificial template comprising a material that can be melted, burned, or leached;
- depositing an investment mold on the sacrificial template, wherein depositing comprises:
- immersing the template in a slurry, the slurry comprising a plurality of colloidal particles and a sufficient quantity of salt to impart an effective charge to the colloidal particles;
- applying a voltage to the template, thereby causing the charged colloidal particles to be deposited on the template to form a green shell;
- and
- sintering the green shell to form the investment mold;
- removing the sacrificial template by melting, burning, or leaching, without damaging the investment mold;
- and
- casting the desired article in the investment mold.
8 more elements
A casting mold, comprising:
- a hollow shell comprising a plurality of partially or fully sintered particles and a measurable quantity of salt residue.
A casting mold, produced by:
- immersing at least a first portion of a template in a first slurry, the first slurry comprising
- a plurality of colloidal particles;
- and
- a sufficient quantity of salt to impart an effective charge to the colloidal particles;
- applying a voltage to the template, thereby causing the charged colloidal particles to be deposited on the template to form a green shell about at least the first portion of the template;
- and
- sintering the green shell to form the casting mold having greater mechanical integrity than the green shell.
4 more elements
Dependencies are inferred from the claim text.