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US 6,932,145 B2Granted
Method and apparatus for production of a cast component
AssigneeROLLS-ROYCE plc
InventorsDonald J. Frasier, Matthew Kush, Max Eric Schlienger, Michael Baldwin
Life of this patent
Estimating the term…
Abstract
A system for producing cast components from molten metal. One form of the present invention includes a system for the precision pouring of molten metal within a casting mold.
Claims44
A method for producing a cast component, comprising:
- forming a thin shell ceramic casting mold with a wall thickness less than about 0.060 inches by the photopolymerization of a ceramic filled resin;
- pouring a molten metal into the thin shell ceramic casting mold without providing additional support to the thin shell ceramic casting mold;
- and
- moving a thermal gradient through the molten metal within the thin shell ceramic casting mold to cause solidification into a cast component with a single crystal or directionally solidified microstructure.
1 more element
A method for producing a cast component with a directionally solidified microstructure, comprising:
- forming a thin shell ceramic casting mold with a wall thickness less than about 0.060 inches by the selective laser activation of a ceramic filled resin;
- heating a thermal mold carrier to a first casting temperature;
- positioning the thin shell ceramic casting mold within the thermal mold carrier after said heating;
- insulating the outer surface of the thermal mold carrier after said heating to minimize the transmission of heat from the thermal mold carrier;
- pouring a molten metal into the thin shell ceramic casting mold after said insulating;
- exposing the thermal carrier to an environment having a temperature within a range of about 2600° F. to about 3000° F. after said pouring;
- exposing the thin shell ceramic casting mold to the cool environment by relative movement between the thermal mold carrier and the thin shell ceramic casting mold;
- and
- directionally solidifying the metal within the thin shell ceramic casting.
6 more elements
A method for producing a cast component, comprising:
- forming a free form fabricated thin shell ceramic casting mold with an integrally formed casting core and having a molten metal receiving cavity, the casting core extending into the molten metal receiving cavity to form at least one opening in the cast component, the thin shell ceramic casting mold having an outer wall with a thickness less than about 0.060 inches;
- pouring a molten metal into the molten metal receiving cavity without providing additional mechanical support to the thin shell ceramic casting mold;
- and
- solidifying the molten metal within the molten metal receiving cavity and around the integral casting core.
1 more element
A method for producing a cast component, comprising:
- forming a free form fabricated ceramic casting mold with a thin outer wall and at least one casting core integrally formed with the outer wall and having a molten metal receiving cavity disposed between the outer wall and the at least one casting core, said forming produces the thin outer wall with a thickness of about 0.020 inches;
- pouring a molten metal into the molten metal receiving cavity without providing additional mechanical support to the thin shell ceramic casting mold;
- and
- solidifying the molten metal within the molten metal receiving cavity and around the integral casting core.
1 more element
A method for producing a cast component, comprising:
- forming a free form fabricated ceramic casting mold with a thin outer wall and at least one casting core integrally formed with the outer wall and having a molten metal receiving cavity disposed between the outer wall and the at least one casting core, wherein the thin outer wall has a thickness less than about 0.060 inches;
- pouring a molten metal into the molten metal receiving cavity without providing additional mechanical support to the thin shell ceramic casting mold core, wherein the molten metal pressure is within a range of about three to about twenty-four inches of nickel;
- and
- solidifying the molten metal within the molten metal receiving cavity and around the integral casting core.
1 more element
Dependencies are inferred from the claim text.