Composite casting method

Abstract

A method of making a composite casting wherein a casting mold is provided having a melt-receiving mold cavity and a preformed metallic or intermetallic insert located in a predetermined position in the mold cavity. A melt is introduced into the mold cavity about the insert and is solidified to provide a composite casting having one or more interfaces between the insert, or an insert positioning member, and cast/solidified metal about the insert. The interface is exposed on or communicates with an exterior surface of the composite casting. After separation from the mold, the composite casting is subjected to a sealing operation to gas-tight seal the interface(s) at the exterior casting surface. For example, the interface can be sealed by providing fused material at the interface. After the interface(s) is (are) sealed, the composite casting is subjected to elevated temperature and isostatic gas pressure conditions effective to produce a sound, void-free, contamination-free metallurgical bond between the insert and the cast melt thereabout. The previously sealed interface(s) prevent the pressurizing gas from entering and migrating between the insert and the cast melt so as to enable formation of the sound, void-free, contamination-free bond.

Dependencies are inferred from the claim text.