Back to results
US 6,814,131 B2Granted
Investment casting mold and method of manufacture
AssigneeBuntrock Industries, Inc.
InventorJohn Vandermeer
Life of this patent
Estimating the term…
Abstract
The invention relates to a investment casting molds and their method of manufacture. The method entails mixing refractory fiber, glass fiber, and refractory filler to form a dry blend; mixing the dry blend with an aqueous colloidal silica sol to form a refractory prime coat slurry, and employing the refractory slurry to produce an investment casting mold.
Claims17
A method of manufacture of an investment casting mold comprising,
- mixing refractory fiber, glass fiber, and refractory filler to form a first dry blend,
- mixing refractory fiber, glass fiber, and refractory filler to form a second dry blend which may be the same or different from the first dry blend,
- mixing the first dry blend with an aqueous colloidal silica sol to form a refractory prime coat slurry,
- mixing the second dry blend with an aqueous colloidal silica sol to form a refractory back-up coat slurry which may be the same or different from the refractory prime coat slurry,
- applying a coating of the prime coat slurry onto an expendable pattern of thermoplastic material to produce a prime coated preform,
- applying a stucco of refractory material onto the prime coated preform,
- drying the stuccoed, prime coated preform,
- applying a coating of the refractory back-up coat slurry onto the stuccoed, prime coated preform to produce a refractory back-up coated preform,
- applying a stucco of refractory material onto the back-up coated preform to produce a stuccoed, back-up coated preform,
- drying the stuccoed, refractory back-up coated preform,
- removing the expendable pattern from the refractory back-up coated preform to produce a green shell mold, and
- heating the green shell mold to a temperature sufficient to produce a fired ceramic shell mold.
9 more elements
A method of manufacture of an investment casting mold comprising,
- mixing Wall astonite refractory fiber, glass fiber, and frised silica refractory filler to form a dry blend,
- mixing a portion of the dry blend with an aqueous colloidal silica sol which has a solids content of 45%, a pH of 9.5 and a titratable Na2O content of 0.2% to form a refractory prime coat slurry,
- mixing another portion of the dry blend with the aqueous colloidal silica sol to form a refractory back-up coat slurry,
- applying a coating of the prime coat slurry onto an expendable pattern of thermoplastic material to produce a prime coated preform,
- applying a stucco of refractory material onto the prime coated preform,
- drying the resulting stuccoed, prime coated preform,
- applying a coating of refractory back-up coat slurry Onto the stuccoed, prime coated preform to produce a refractory back-up coated preform,
- applying a stucco of refractory material onto the back-up coated preform to produce a stuccoed, back-up coated preform,
- drying the stuccoed, refractory back-up coated preform,
- removing the thermoplastic pattern from the refractory back-up coated preform to produce a green shell mold, and
- heating the green shell mold to a temperature sufficient to produce a ceramic shell mold.
8 more elements
A method of manufacture of an investment casting mold comprising,
- mixing glass fiber, fused silica refractory filler and rice hull ash to form a dry blend,
- mixing a portion of the dry blend with an aqueous colloidal silica sol binder that has a pH of 10.5, a solids content of 40% and a titratable Na2O content of 0.33%, an average particle size of about 40 nm, a particle size distribution of about 6 nm to about 190 nm, and a standard deviation of particle size of about 20 nm to form a refractory prime coat slurry,
- mixing another portion the dry blend with the aqueous colloidal silica sol to form a refractory back-up coat slurry,
- applying a coating of the prime coat slurry onto an expendable pattern of thermoplastic material to produce a prime coated preform,
- applying a stucco of refractory material onto the prime coated preform,
- drying the resulting stuccoed, prime coated preform,
- applying a coating of refractory back-up coat slurry onto the stuccoed, prime coated preform to produce a refractory back-up coated preform,
- applying a stucco of refractory material onto the back-up coated preform to produce a stuccoed, back-up coated preform,
- drying the stuccoed, refractory back-up coated preform,
- removing the thermoplastic pat-tern from the refractory back-up coated preform to produce a green shell mold, and
- heating the green shell mold to a temperature sufficient to produce a ceramic shell mold.
8 more elements
A method of manufacture of an investment casting mold comprising,
- mixing refractory fiber and glass fiber to form a first dry blend,
- mixing refractory fiber and glass fiber to form a second dry blend which may be the same or different from the first dry blend,
- mixing the first dry blend with a mixture of aqueous colloidal silica sol and refractory filler to form a refractory prime coat slurry,
- mixing the second dry blend with a mixture of aqueous colloidal silica sol and refractory filler an aqueous colloidal silica sol to form a refractory back-up coat slurry which may be the same or different from the refractory prime coat slurry,
- applying a coating of the prime coat slurry onto an expendable pattern of thermoplastic material to produce a prune coated preform,
- applying a stucco of refractory material onto the prime coated preform,
- drying the resulting stuccoed, prime coated preform,
- applying a coating of the refractory back-up coat slurry onto the stuccoed, prime coated preform to produce a back-up coated preform,
- applying a stucco of refractory material onto the back-up coated preform to produce a stuccoed, back-up coated preform,
- drying the stuccoed, refractory back-up coated preform,
- removing the expendable pattern from the refractory back-up coated preform to produce a green shell mold, and
- heating the green shell mold to a temperature sufficient to produce a fired ceramic shell mold.
9 more elements
A method of manufacture of an investment casting mold comprising,
- maxing refractory fiber and refractory filler to form a first dry blend,
- mixing refractory fiber and refractory filler to form a second dry blend which may be the same or different from the first dry blend,
- mixing the first dry blend with an aqueous colloidal silica sol to form a refractory prime coat slurry,
- mixing the second dry blend with an aqueous colloidal silica sol to form a refractory back-up coat slurry which may be the same or different from the refractory prime coat slurry,
- applying a coating of the prime coat slurry onto an expendable pattern of thermoplastic material to produce a prime coated preform,
- drying the resulting stuccoed, prime coated preform,
- applying a coating of the refractory back-up coat slurry onto prime coated preform to produce a refractory back-up coated preform,
- drying the refractory back-up coated preform,
- removing the expendable pattern from the refractory back-up coated preform to produce a green shell mold, and
- heating the green shell mold to a temperature sufficient to produce a fired ceramic shell mold.
7 more elements
A method of manufacture of an investment casting mold comprising,
- mixing fiber and refractory filler to form a first dry blend,
- mixing fiber and refractory filler to form a second dry blend which may be the same or different from the first dry blend,
- mixing the first dry blend with an aqueous colloidal silica sol to form a refractory prime coat slurry,
- mixing the second dry blend with an aqueous colloidal silica sol to form a refractory back-up coat slurry which may be the same or different from the refractory prime coat slurry,
- applying a coating of the prime coat slurry onto an expendable pattern of thermoplastic material to produce a prime coated preform,
- applying a stucco of refractory material onto the prime coated preform,
- drying the resulting stuccoed, prime coated preform,
- applying a coating of the refractory back-up coat slurry onto the stuccoed, prime coated preform to produce a refractory back-up coated preform,
- applying a stucco of refractory material onto the back-up coated preform to produce a stuccoed, back-up coated preform,
- drying the stuccoed, refractory back-up coated preform,
- removing the expendable pattern from the refractory back-up coated preform to produce a green shell mold, and
- heating the green shell mold to a temperature sufficient to produce a fired ceramic shell mold.
9 more elements
Dependencies are inferred from the claim text.