Method for preparation of casting tooling
AssigneeMassachusetts Institute of Technology
InventorJames A. Cornie
Life of this patent
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Abstract
A method for producing semi-permanent casting tooling, including the steps of blending a high char resin with a refractory powder to form a plastic moldable material; shaping the plastic moldable material to form a green tooling body; and heating the green tooling body to convert the high char resin into carbon char to form reusable casting tooling. The casting tooling can be used in casting processes including die casting, permanent mold casting and pressure infiltration casting.
Claims29
A method for directly preparing reusable high density casting tooling comprising the steps of:
- (1) providing a high char resin, said high char resin having a char yield in a range of from about 60% by weight to about 90% by weight carbon remaining after heating said high char resin to at least a temperature at which said high char resin decomposes;
- (2) providing a refractory powder selected from the group consisting of silicon carbide, silicon nitride, titanium carbide, titanium nitride, boron carbide, graphite, zirconia, yttria and mixtures thereof, said refractory powder comprising particles having a mean particle size less than about 180 .mu.m;
- (3) blending said high char resin with said refractory powder to form a plastic moldable material;
- (4) shaping said plastic moldable material to form a green tooling body;
- and
- (5) heating said green tooling body to convert said high char resin into a carbon char to form directly said reusable high density casting tooling.
A method for directly preparing reusable high density casting tooling for pressure casting comprising the steps of:
- (1) blending a high char resin with a refractory powder to form a moldable material said refractory powder comprising particles having a mean particle size of less than about 180 microns, said high char resin having a char yield in a range of from about 60% by weight to about 90% by weight carbon remaining after heating said high char resin to at least a temperature where said high char resin decomposes;
- (2) shaping said moldable material to form a green tooling body;
- and
- (3) heating said green tooling body to convert said high char resin into a carbon char to form said reusable high density casting tooling.
A method for directly preparing reusable high density casting tooling comprising the steps of:
- (1) providing a high char resin comprising a filler, said high char resin having a char yield in a range of from about 60% by weight to about 90% by weight carbon remaining after heating said high char resin to at least a temperature where said high char resin decomposes;
- (2) blending said high char resin with a refractory powder to form a moldable material;
- (3) shaping said moldable material to form a green tooling body;
- and
- (4) heating said green tooling body to convert said high char resin into a carbon char to form said reusable high density casting tooling.
A method for preparing reusable high density casting tooling comprising the steps of:
- (1) providing a high char resin;
- (2) blending said high char resin with a refractory powder comprising particles having a first mean diameter and a refractory powder comprising particles having a second mean diameter to form a tightly packed moldable material;
- (3) shaping said tightly packed moldable material to form a green tooling body;
- and
- (4) heating said green tooling body to convert said high char resin into a carbon char to form said reusable high density casting tooling.
Dependencies are inferred from the claim text.