System, method, and apparatus for leaching cast components

A method, comprising:

• utilizing least one of a water jet removal and a laser drilling removal to remove at least a portion of a virtual pattern cast (VPC) shell from a cast component;
• exposing the cast component to a KOH bath and a high pressure water wash to remove an internal core material from the cast component and at least a portion of a VPC shell remainder;
• exposing the cast component to a high agitation KOH solution and the high pressure water wash, the high agitation KOH solution comprising a KOH solution subject to intermittent boiling caused by at least one of heating the KOH solution and reducing a pressure in a submersion vessel;
• applying an electroless nickel-boron coating to the cast component;
• applying an electrolytic palladium coating to the cast component;
• and
• exposing the cast component to the high agitation KOH solution to remove the VPC shell remainder and an internal core material remainder.

A system, comprising:

• a water jet and a laser drill adapted to remove at least a portion of a virtual pattern cast (VPC) shell from a cast component;
• a submersion vessel adapted to contain the cast component and a quantity of a leaching solution;
• a high pressure water wash operable to wash the cast component within the submersion vessel;
• the submersion vessel further adapted to accept at least one of a heat input and a pressure reduction to produce a first high agitation leaching solution;
• the submersion vessel further adapted to contain a quantity of an electroless nickel-boron coating solution and a quantity of an electrolytic palladium coating solution;
• and
• the submersion vessel further adapted to contain the cast component and a second high agitation leaching solution for a period of approximately 3 days.

A system, comprising:

• a focused removal means for removing at least a portion of a virtual pattern cast (VPC) shell from a cast component;
• a first caustic treatment means for exposing the cast component to a caustic bath and a high pressure water wash to remove an internal core material from the cast component and to remove at least a portion of a VPC shell remainder;
• at least one of a heating means and a pressure adjustment means for producing a high agitation caustic solution comprising a caustic solution subject to intermittent boiling;
• a second caustic treatment means for exposing the cast component to the high agitation caustic solution and to the high pressure water wash;
• an electroless coating means for applying an electroless nickel-boron coating to the cast component;
• an electrolytic coating means for applying an electrolytic palladium coating to the cast component;
• and
• a third caustic treatment means for exposing the cast component to the high agitation caustic solution for an extended period to remove the VPC shell remainder and an internal core material remainder.