Abstract: An apparatus for casting a part that includes a first housing, a second housing, a handling system and a cooling apparatus. The first housing defines a first chamber. The first chamber is configured to receive a melt heater and a mold heater. The second housing is configured to move between a first position and a second position such that when the second housing is in the first position, the first housing is open such that a mold can be inserted therein and when the second housing is in the second position, the second housing and the first housing define a second chamber. The cooling apparatus is configured to be positioned within the second chamber.

Abstract: A method for casting a part, that includes the steps of: introducing a mold into a first housing; engaging the first housing with a second housing to define a second chamber; melting an ingot within the furnace; reducing pressure within the second chamber to a first predetermined pressure; pouring at least a portion of the melted ingot into the mold; adding an gas to the second chamber to raise the pressure to a second predetermined pressure; moving the mold such that it is engaged with the means for cooling; and solidifying the liquid metal within the mold.

Abstract: The present disclosure relates to a method of forming a cast component and a method of forming a casting mold. The method is performed by connecting at least one wax gate component to a ceramic core-shell mold. The ceramic core-shell mold includes at least a filter, first core portion, a first shell portion, and at least one first cavity between the core portion and the first shell portion. The core-shell mold may manufactured using an additive manufacturing process and may include an integrated ceramic filter. At least a portion of the ceramic core-shell mold and the wax gate component is coated with a second ceramic material. The wax gate component is then removed to form a second cavity in fluid communication with the first cavity.

Abstract: A method for producing a cast component is provided. The method includes attaching a ceramic mold to a seed crystal body, the ceramic mold including a cavity defining the shape of the cast component and a seed crystal body interface having a complementary shape to the seed crystal body such that the seed crystal body may be capable of supporting the ceramic mold in a casting oven. The method also includes pouring a liquid metal into the mold such that the crystal seed portion contributes to controlled crystallization of the cast component.

Abstract: A method of forming a cast component and a method of forming a casting mold is provided. The method is performed by connecting at least one wax gate component to a ceramic core-shell mold. The ceramic core-shell mold includes at least a filter, a first core portion, a first shell portion, and at least one first cavity between the core portion and the first shell portion. The ceramic core-shell mold may be manufactured using an additive manufacturing process and may include an integrated ceramic filter. At least a portion of the ceramic core-shell mold and the wax gate component is coated with a second ceramic material. The wax gate component is then removed to form a second cavity in fluid communication with the first cavity.

Abstract: Methods for creating a cast component, along with the resulting cast components, are provided. The method may provide for a controlled grain structure in the resulting cast component. The methods may include heating at least a first portion mold under controlled conditions, such as when the first portion of the mold is buried in a ceramic powder.

Abstract: Methods for creating a cast component, along with the resulting cast components, are provided. The method may include heating a mold having a cavity therein; supplying a first molten metal material into the cavity of the mold such that the first molten metal material is directed to a first portion of the cavity of the mold; supplying a second molten metal material into the cavity of the mold such that the second molten metal material is directed to a second portion of the cavity of the mold, wherein the first molten metal material is compositionally different than the second molten metal material; and thereafter, allowing the first molten metal material and the second molten metal material to form the cast component.

Abstract: The present disclosure generally relates to partial integrated core-shell investment casting molds that can be assembled into complete molds. Each section of the partial mold may contain both a portion of a core and portion of a shell. Each section can then be assembled into a mold for casting of a metal part. The partial integrated core-shell investment casting molds and the complete molds may be provided with filament structures corresponding to cooling hole patterns on the surface of the turbine blade or the stator vane, which provides a leaching pathway for the core portion after metal casting. The invention also relates to core filaments that can be used to supplement the leaching pathway, for example in a core tip portion of the mold.

Abstract: The present disclosure generally relates to integrated core-shell investment casting molds that provide a filament structure corresponding to a cooling hole pattern in the surface of the turbine blade, stator vane, or shroud. The disclosure also relates to the forming of a ceramic coating on at least a portion of the shell of the core-shell casting mold.

Abstract: The present disclosure generally relates to integrated core-shell investment casting molds that provide a filament structure corresponding to a cooling hole pattern in the surface of the turbine blade, stator vane, or shroud. The disclosure also relates to the forming of a ceramic coating on at least a portion of the shell of the core-shell casting mold.

Abstract: A method of forming a cast component and a method of forming a casting mold is generally provided. The method is performed by plugging or covering an opening in a ceramic core-shell mold. The ceramic core-shell mold includes at least a first core portion, a first shell portion, and at least one first cavity between the core portion and the first shell portion. The core-shell mold may be manufactured using an additive manufacturing process. At least a portion of the ceramic core-shell mold and the plug or cover is coated with a second ceramic material.

Abstract: A method of forming a cast component and a method of forming a casting mold is generally provided. The method is performed by plugging or covering an opening in a ceramic core-shell mold. The ceramic core-shell mold includes at least a first core portion, a first shell portion, and at least one first cavity between the core portion and the first shell portion. The core-shell mold may be manufactured using an additive manufacturing process. At least a portion of the ceramic core-shell mold and the plug or cover is coated with a second ceramic material.

Abstract: The present disclosure generally relates to integrated core-shell investment casting molds that provide tongue or groove structures corresponding, respectively, to groove or tongue structures in the surface of the turbine blade or stator vane, including in locations that are otherwise inaccessible. The groove and tongue structures also provide a pathway to restrict cooling flow between turbine blades to the flowpath.

Abstract: A method for producing a cast component is provided. The method includes attaching a ceramic mold to a seed crystal body, the ceramic mold including a cavity defining the shape of the cast component and a seed crystal body interface having a complementary shape to the seed crystal body such that the seed crystal body may be capable of supporting the ceramic mold in a casting oven. The method also includes pouring a liquid metal into the mold such that the crystal seed portion contributes to controlled crystallization of the cast component.

Abstract: A method for casting a part, that includes the steps of: introducing a mold into a first housing; engaging the first housing with a second housing to define a second chamber; melting an ingot within the furnace; reducing pressure within the second chamber to a first predetermined pressure; pouring at least a portion of the melted ingot into the mold; adding an gas to the second chamber to raise the pressure to a second predetermined pressure; moving the mold such that it is engaged with the means for cooling; and solidifying the liquid metal within the mold.

Abstract: A method for fabricating a ceramic mold is provided. The method includes the steps of contacting a cured portion of a workpiece with a liquid ceramic photopolymer, irradiating a portion of the liquid ceramic photopolymer adjacent to the cured portion through a window contacting the liquid ceramic photopolymer, removing the workpiece from the uncured liquid ceramic photopolymer, and repeating the steps until a ceramic mold is formed. The ceramic mold includes a first opening for creating a cast article and a second opening for receiving a support member.

Abstract: An apparatus for casting a part that includes a first housing, a second housing, a handling system and a means for cooling. The first housing defines a first chamber. The first chamber is configured to receive a melt heater and a mold heater. The second housing is configured to move between a first position and a second position such that when the second housing is in the first position, the first housing is open such that a mold can be inserted therein and when the second housing is in the second position, the second housing and the first housing define a second chamber. The means for cooling is configured to be positioned within the second chamber.

Abstract: The present disclosure generally relates to integrated core-shell investment casting molds that provide a filament structure corresponding to a cooling hole pattern in the surface of the turbine blade, stator vane, or shroud. The disclosure also relates to the forming of a ceramic coating on at least a portion of the shell of the core-shell casting mold.

Abstract: The present disclosure relates to a method of forming a cast component and a method of forming a casting mold. The method is performed by connecting at least one wax gate component to a ceramic core-shell mold. The ceramic core-shell mold includes at least a filter, first core portion, a first shell portion, and at least one first cavity between the core portion and the first shell portion. The core-shell mold may manufactured using an additive manufacturing process and may include an integrated ceramic filter. At least a portion of the ceramic core-shell mold and the wax gate component is coated with a second ceramic material. The wax gate component is then removed to form a second cavity in fluid communication with the first cavity.

Abstract: The present disclosure relates to a method of forming a cast component and a method of forming a casting mold. The method is performed by connecting at least one wax gate component to a ceramic core-shell mold. The ceramic core-shell mold includes at least a filter, first core portion, a first shell portion, and at least one first cavity between the core portion and the first shell portion. The core-shell mold may manufactured using an additive manufacturing process and may include an integrated ceramic filter. At least a portion of the ceramic core-shell mold and the wax gate component is coated with a second ceramic material. The wax gate component is then removed to form a second cavity in fluid communication with the first cavity.