Investment casting refractory material
AssigneeWiSys Technology Foundation, Inc.
InventorsDaniel Scott McGuire, Eric Ernst Hellstrom
Life of this patent
Estimating the term…
Abstract
An investment casting method involves producing a casting shell by applying a hardenable refractory material to a sacrificial pattern. The casting shell having a plurality of phosphate bonds in the hardenable refractory material, which provide increased structural integrity during casting and improved frangibility during shell removal. The casting shell may also have a plurality of gaseous pockets suspended in the refractory material, which do not degrade the structural integrity during casting and provide improved frangibility during shell removal.
Claims20
A liquid investment casting refractory material for lost wax casting of high-temperature molten materials comprising:
- a liquid refractory material containing a fused silica, a dead burned magnesium oxide, a surfactant, an acid powder and a monobasic magnesium phosphate, in an amount providing a flowable state such that the liquid refractory material will flow about an outer surface of an investment casting wax pattern;
- wherein the liquid refractory material as configured hardens for use as a shell having a plurality of phosphate bonds at an ambient temperature lower than a melting point of the investment casting wax pattern, the shell comprising a cavity having an inner surface complementary to an outer surface of the investment casting wax pattern for receiving casting of a high-temperature molten material, having a temperature of greater than 1500° F., therein.
A pre-casting system for use with lost mold casting of high-temperature molten materials comprising:
- an amount of a liquid refractory material containing a fused silica, a dead burned magnesium oxide, a surfactant, an acid powder and a monobasic magnesium phosphate, providing a flowable state such that the liquid refractory material will flow about an outer surface of an investment casting pattern;
- wherein the liquid refractory material as configured hardens for use as a shell having a plurality of phosphate bonds at an ambient temperature lower than a melting point of the investment casting pattern, the shell comprising a cavity having an inner surface complementary to an outer surface of the investment casting wax pattern for receiving casting of a high-temperature molten material, having a temperature of greater than 1500° F., therein.
A pre-casting system for use with lost mold casting of high-temperature molten materials comprising:
- a liquid refractory material containing at least 60% by weight of a fused silica, approximately 5% by weight of a dead burned magnesium oxide, a surfactant, an acid and at least 5% by weight of a monobasic magnesium phosphate, in an amount providing a flowable state such that the liquid refractory material will flow about an outer surface of an investment casting wax pattern;
- wherein the liquid refractory material as configured hardens for use as a shell having a plurality of phosphate bonds at an ambient temperature lower than a melting point of the investment casting wax pattern, the shell comprising a cavity having an inner surface complementary to an outer surface of the investment casting wax pattern for receiving casting of a high-temperature molten material, having a temperature of greater than 1500° F., therein.
Dependencies are inferred from the claim text.