Aerospace sand casting support
AssigneeHamilton Sundstrand Corporation
InventorRobert E. Lafurge, JR.
Life of this patent
Estimating the term…
Abstract
A component casting apparatus includes a mold to receive a molten solid for casting a component. The mold includes a first sacrificial layer to define a housing of the component and a second sacrificial layer to form at least one core passage of the component in response to contact from the molten solid. The component casting apparatus further includes a trusset disposed against an outer surface of the second sacrificial layer and formed from metal to support the second sacrificial layer.
Claims19
A component casting apparatus, comprising:
- a mold to receive a molten material for casting a component, the mold including a first sacrificial layer to define a housing of the component and a second sacrificial layer to form at least one core passage of the component in response to contact from the molten material, the first and second sacrificial layers defining a metal fusing area between one another to receive the molten material and forms a passage wall of the at least one core passage, the second sacrificial layer being surrounded by the first sacrificial layer and extending along a first direction and having a first diameter to define a hollowed region of the at least one core passage of the component in response to contact from the molten material;
- and
- a trusset disposed against an outer surface of the second sacrificial layer without extending through the second sacrificial layer, the trusset formed from metal to support the second sacrificial layer, and including a frame extending in a direction perpendicular to the first direction and disposed between the first and second sacrificial layers, the frame including a first portion in contact with the first sacrificial layer and a second portion in contact with the second sacrificial layer,
- wherein the second portion includes at least one support surface that extends into the metal fusing area and contacts the second sacrificial layer.
3-7. (canceled)
(canceled)
The component casting apparatus of claim 4, wherein the first and second sacrificial layers are formed from sand.
A trusset to support a core structure having radius and length extending perpendicular to the radius, the trusset comprising:
- a frame extending in a direction perpendicular to the length of the core structure, the frame comprising:
- an upper portion to contact a first sacrificial layer of a casting apparatus;
- and
- a lower portion to contact a second sacrificial layer of the casting apparatus
- wherein the second sacrificial layer is surrounded by the first sacrificial layer, the second sacrificial layer extending along a first direction and having a first diameter to define a hollowed region of the core structure,
- wherein the first and second sacrificial layers define a metal fusing area between one another to receive the molten material and form a passage wall of the core structure, the second portion includes at least one support surface that extends into the metal fusing area and contacts the second sacrificial layer, and
- wherein the trusset includes a frame extending in a direction perpendicular to the first direction and disposed between the first and second sacrificial layers, the frame including a first portion in contact with the first sacrificial layer and a second portion in contact with the second sacrificial layer.
A method of casting a component including a core passage, the method comprising:
- forming at least one core structure having a predetermined diameter for defining a hollow region of the core passage;
- coupling a trusset to an outer surface of the core structure;
- covering the core structure and the trusset with a molten metal to melt the trusset;
- solidifying the molten metal and melted trusset to form the core passage such that trusset is integrally formed thereto,
- wherein the second sacrificial layer is surrounded by the first sacrificial layer, the second sacrificial layer extending along a first direction and having a first diameter to define a hollowed region of the core structure,
- wherein the first and second sacrificial layers define a metal fusing area between one another to receive the molten material and form a passage wall of the core structure, the second portion includes at least one support surface that extends into the metal fusing area and contacts the second sacrificial layer, and
- wherein the trusset includes a frame extending in a direction perpendicular to the first direction and disposed between the first and second sacrificial layers, the frame including a first portion in contact with the first sacrificial layer and a second portion in contact with the second sacrificial layer.
Dependencies are inferred from the claim text.