# US 8,784,066 B2 · Die casting to produce a hybrid component

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- Number: US 8,784,066 B2
- Document ID: US8784066B2
- Status: Granted
- Kind: B2
- Application number: 12/940,289
- Filed: 2010-11-05
- Published: 2012-05-10
- Granted: 2014-07-22
- Earliest claimed: 2010-11-05
- Assignees: United Technologies Corporation
- Applicants: Mario P. Bochiechio; Steven J. Bulliad; Carl R. Verner
- Inventors: Mario P. Bochiechio; Steven J. Bulliad; Carl R. Verner
- Web page: https://patentgrep.com/patent/US8784066B2

## CPC

- B22D 17/24: Accessories for locating and holding cores or inserts
- B22D 19/04: for joining parts
- Y10T 29/49337: Composite blade
- B22D: CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES (shaping of plastics or substances in a plastic state B29C; metallurgical processing, selection of substances to be added to metal C21, C22)
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

An example die casting system includes a die that defines a cavity having a first section and a second section. The first section is configured to receive a first portion of a component. The second section is configured to receive a molten material. The die holds the molten material as the molten material solidifies to form a second portion of the component.

## Claims

### Claim 1

A die casting system, comprising:
a die that defines a cavity having a first section and a second section, the first section configured to receive a first portion of a component, and the second section configured to receive a molten material, wherein the die holds the molten material as the molten material solidifies to form a second portion of the component.

### Claim 2 (depends on 1)

The die casting system of claim 1, wherein the component is an aircraft component.

### Claim 3 (depends on 1)

The die casting system of claim 1, wherein the component is a gas turbine engine component.

### Claim 4 (depends on 1)

The die casting system of claim 1, wherein the component is a blade assembly.

### Claim 5 (depends on 4)

The die casting system of claim 4, wherein the first section forms at least a blade portion of the airfoil assembly, and the second section forms at least a shroud portion of the airfoil assembly.

### Claim 6 (depends on 1)

The die casting system of claim 1, wherein the first portion of the component comprises a cobalt alloy.

### Claim 7 (depends on 6)

The die casting system of claim 6, wherein the second portion of the component comprises a nickel alloy.

### Claim 8 (depends on 6)

The die casting system of claim 6, wherein the first portion of the component comprises a metal that is less dense than the second portion of the component.

### Claim 9 (depends on 1)

The die casting system of claim 1, wherein the first section is investment cast.

### Claim 10 (depends on 1)

The die casting system of claim 1, wherein the molten material held in the second section melts some of the first portion.

### Claim 11

A method of forming a turbomachine component, comprising
holding a first portion of a component within a first section of a cavity; and
die casting a second portion of the component within a second section of the cavity, wherein the first portion comprises a first material and the second portion comprises a second material that is different than the first material.

### Claim 12 (depends on 11)

The method of claim 11, including melting a least some of the first material using the second material.

### Claim 13 (depends on 11)

The method of claim 11, including repairing the component by securing a new second portion to a used first portion.