Rapid prototype casting
AssigneeHoneywell International Inc.
InventorsMilton Ortiz, Malak F. Malak, Steve H. Halfmann
Life of this patent
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Abstract
Methods for rapid prototype casting metal components, wherein the metal components are cast in a secondary ceramic mold, the secondary ceramic mold is cast in a primary mold, and the primary mold is formed by rapid prototyping or rapid manufacturing. The secondary ceramic mold may comprise a one-piece integral shell and core(s), and the metal components may have at least one hollow portion or void therein, such as a hollow airfoil for a gas turbine engine.
Claims49
A method for forming a metal component, comprising:
- a) forming a primary mold by a rapid prototyping process such that the primary mold comprises a primary shell and a primary core that is formed integral with said primary shell;
- b) forming a secondary mold from said primary mold by casting secondary mold material in said primary mold;
- and
- c) casting said metal component in said secondary mold.
A method for casting a metal component, comprising:
- a) forming a one-piece primary mold via a rapid prototyping process such that said primary mold includes a primary shell and a primary core that is formed integral with said primary shell;
- b) forming a secondary mold from said primary mold, wherein said secondary mold includes a secondary shell and a secondary core formed integral with said secondary shell, and said secondary mold comprises a ceramic;
- and
- c) casting said metal component in said secondary mold, wherein said metal component includes at least one component internal void, and said secondary core defines said at least one component internal void.
A method for rapid prototyping a hollow metal airfoil, comprising:
- a) forming a one-piece primary mold via a rapid prototyping process such that said primary mold includes a primary shell and a primary core that is formed integral with said primary shell;
- b) gelcasting a secondary mold from said primary mold, wherein said secondary mold includes a secondary shell, a secondary core formed integral with said secondary shell, and a plurality of secondary registration portions for registering said secondary shell with said secondary core, and wherein said secondary mold comprises a ceramic;
- and
- c) casting said metal airfoil in said secondary mold, wherein said metal airfoil includes an external surface having a plurality of film cooling holes therein, and at least one component internal void in communication with said film cooling holes, wherein said film cooling holes are formed by said step c).
A method for forming a secondary mold, comprising:
- a) forming a one-piece primary mold by a rapid prototyping process such that said primary mold has a primary core, a primary shell formed integral with said primary core, and a primary outer void disposed between said primary shell and said primary core;
- and
- b) gelcasting said secondary mold in said primary mold, said secondary mold having a secondary core, a secondary shell formed integral with said secondary core, and at least one secondary registration portion for registering said secondary shell with said secondary core, wherein said primary outer void defines said secondary shell.
Dependencies are inferred from the claim text.