Back to results
US 2024/0269732 A1Published application
Mullite shell systems for investment castings and methods
AssigneeCarbo Ceramics Inc.
InventorsRay JANSON, Ryan CANFIELD
Life of this patent
Estimating the term…
Abstract
A mullite shell mold for casting includes a facecoat layer containing ceramic flour. The mullite shell mold also includes a first layer disposed on the facecoat layer. The first layer can contain sintered ceramic media. The facecoat layer and the first layer can each contain less than 1 wt % crystalline silica.
Claims20
A shell mold, the shell mold comprising:
- a facecoat layer comprising ceramic flour;
- and
- a first layer overlaying the facecoat layer, the first layer comprising sintered ceramic media, wherein:
- the facecoat layer and the first layer each contain less than 1 wt % crystalline silica, and
- the sintered ceramic media comprises sintered, substantially round and spherical bauxite particles having a mesh size from about 10 mesh to about 100 mesh.
2 more elements
A method of manufacturing a casting mold, comprising:
- introducing a ceramic flour with a colloidal silica to provide a facecoat slurry;
- depositing the facecoat slurry onto a pattern comprising a thermoplastic material to provide a facecoat layer disposed on the pattern;
- and
- depositing a stucco material onto the facecoat layer to provide a first layer disposed on the facecoat layer, the stucco material comprising sintered, substantially round and spherical bauxite particles having a mesh size from about 10 mesh to about 100 mesh.
1 more element
A method of manufacturing, comprising:
- reducing the size of a ceramic material;
- wetting the material to produce a slurry, wherein the slurry has a solids content from about 40 wt % to about 60 wt %;
- pelletizing the slurry to produce green pellets;
- drying or calcining the green pellets in an atmosphere containing oxygen to form dried green pellets;
- sintering the dried green pellets to provide sintered pellets, the sintered pellets comprising substantially round and spherical particles selected from the group consisting of kaolin, bauxite, or any combination thereof;
- and
- grinding the sintered pellets to form a flour.
4 more elements
Dependencies are inferred from the claim text.