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US 8,327,911 B2Granted
Method for forming a cast article
AssigneeROLLS-ROYCE plc
InventorsMatthew T. Kush, Max Eric Schlienger, Paul Anthony Withey
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Abstract
One embodiment of the present invention is a unique method for forming a cast porous article. Other embodiments include apparatuses, systems, devices, hardware, methods, and combinations for forming cast porous articles. Further embodiments, forms, features, aspects, benefits, and advantages of the present application shall become apparent from the description and figures provided herewith.
Claims24
A method for forming a porous article, comprising:
- freeform fabricating a ceramic mold having a controlled porosity distribution including a distribution of interconnected nodules using a predetermined definition of porosity configuration;
- sintering the ceramic mold;
- supplying a molten alloy to the sintered mold;
- and
- removing the ceramic mold and the interconnected nodules to yield a cast metallic article having a plurality of interconnected pores.
2 more elements
A method for forming a gas turbine engine blade casting, comprising:
- defining a distribution of interconnected nodules spaced apart by a first plurality of interconnected pores;
- freeform fabricating a ceramic mold, the ceramic mold including an airfoil portion having the defined distribution of interconnected nodules spaced apart by the first plurality of interconnected pores;
- supplying a molten alloy to the ceramic mold;
- solidifying the molten alloy;
- and
- leaching the interconnected nodules to yield a metallic airfoil having a second plurality of interconnected pores extending therethrough.
3 more elements
A method for forming a gas turbine engine blade casting, comprising:
- free-forming a ceramic mold having a plurality of interconnected nodules based on a defined distribution of the interconnected nodules;
- supplying a molten alloy to the mold;
- and
- removing the plurality of interconnected nodules to yield a metallic airfoil having a plurality of interconnected pores extending therethrough.
1 more element
Dependencies are inferred from the claim text.