Abstract: Various techniques are provided for creating fugitive foam patterns for use in investment casting operations. In certain illustrative embodiments, a fugitive foam pattern is assembled from independently formed portions. A first section is formed in a mold. Once cured, a mating surface of the first section is exposed to the cavity of a second mold and the section is formed. The second section integrally adheres to the first section. The process is repeated as necessary. In alternative embodiments, a channel is created in a foam pattern using a temporary core that is removed without chemical leaching. The core material comprises water-soluble materials, acid-soluble materials, low-melting point materials, or a combination thereof. A pattern may also be created by inserting foam around a core that remains with the foam pattern.

Abstract: A composite structure comprises a closed-cell foam pattern having a skin, and a layer laminated to the skin of the foam pattern. The laminated layer may comprise a continuous layer, a discontinuous layer, a coating, a powder/particulate coating, another closed-cell foam pattern having a skin, etc. Also, the laminated layer may comprise a surface coating applied in-mold or post-mold to provide a composite structure that exhibits wear resistance, corrosion resistance, weather proofing, UV protection, and protection from delaminating or discoloring. A strengthening agent can be present throughout the foam.

Abstract: A method of creating a foam pattern comprises mixing a polyol component and an isocyanate component to form a liquid mixture. The method further comprises placing a temporary core having a shape corresponding to a desired internal feature in a cavity of a mold and inserting the mixture into the cavity of the mold so that the mixture surrounds a portion of the temporary core. The method optionally further comprises using supporting pins made of foam to support the core in the mold cavity, with such pins becoming integral part of the pattern material simplifying subsequent processing. The method further comprises waiting for a predetermined time sufficient for a reaction from the mixture to form a foam pattern structure corresponding to the cavity of the mold, wherein the foam pattern structure encloses a portion of the temporary core and removing the temporary core from the pattern independent of chemical leaching.

Abstract: A method of creating a foam pattern comprises mixing a polyol component and an isocyanate component to form a liquid mixture. The method further comprises placing a temporary core having a shape corresponding to a desired internal feature in a cavity of a mold and inserting the mixture into the cavity of the mold so that the mixture surrounds a portion of the temporary core. The method optionally further comprises using supporting pins made of foam to support the core in the mold cavity, with such pins becoming integral part of the pattern material simplifying subsequent processing. The method further comprises waiting for a predetermined time sufficient for a reaction from the mixture to form a foam pattern structure corresponding to the cavity of the mold, wherein the foam pattern structure encloses a portion of the temporary core and removing the temporary core from the pattern independent of chemical leaching.

Abstract: A foam material comprises a liquid polymer and a liquid isocyanate which is mixed to make a solution that is poured, injected or otherwise deposited into a corresponding mold. A reaction from the mixture of the liquid polymer and liquid isocyanate inside the mold forms a thermally collapsible foam structure having a shape that corresponds to the inside surface configuration of the mold and a skin that is continuous and unbroken. Once the reaction is complete, the foam pattern is removed from the mold and may be used as a pattern in any number of conventional casting processes.

Abstract: A foam material comprises a liquid polymer and a liquid isocyanate which is mixed to make a solution that is poured, injected or otherwise deposited into a corresponding mold. A reaction from the mixture of the liquid polymer and liquid isocyanate inside the mold forms a thermally collapsible foam structure having a shape that corresponds to the inside surface configuration of the mold and a skin that is continuous and unbroken. Once the reaction is complete, the foam pattern is removed from the mold and may be used as a pattern in any number of conventional casting processes.

Abstract: A co-continuous metal-ceramic (CCMC) article resulting from a chemical reaction between a ceramic preform and a molten metal is disclosed. The ceramic preform is produced by intermixing a precursor material and a particulate ceramic material, shaping that mixture into a predetermined configuration, and transforming the precursor material into a ceramic matrix. Shaping the preform, whether through a simple molding process, or through a sophisticated rapid prototyping process, is disclosed. CCMC articles having regions of different composition and/or properties are also disclosed.

Abstract: A ceramic article resulting from a chemical interaction between a particulate ceramic material and a ceramic matrix material is described. The ceramic matrix results from at least partial chemical transformation of a precursor material. A chemical bond between the ceramic matrix and the particulate ceramic material is developed during manufacture. The configuration of the ceramic article is developed through use of a rapid prototyping process. A ceramic article comprising different compositions in two or more regions of the article is described. A manufacturing process comprising the steps employed to produce such a ceramic article is also described. The ceramic article described herein is particularly suited for use as a mold for metal casting. The manufacturing process disclosed herein enables production of such a mold within a matter of hours, rather than days, as required by prior art casting technologies.

Abstract: A ceramic article resulting from a chemical interaction between a particulate ceramic material and a ceramic matrix material is described. The ceramic matrix results from at least partial chemical transformation of a precursor material. A chemical bond between the ceramic matrix and the particulate ceramic material is developed during manufacture. The configuration of the ceramic article is developed through use of a rapid prototyping process. A ceramic article comprising different compositions in two or more regions of the article is described. A manufacturing process comprising the steps employed to produce such a ceramic article is also described.

Abstract: A co-continuous metal-ceramic (CCMC) article resulting from a chemical reaction between a ceramic preform and a molten metal is disclosed. The ceramic preform is produced by intermixing a precursor material and a particulate ceramic material, shaping that mixture into a predetermined configuration, and transforming the precursor material into a ceramic matrix. Shaping the preform, whether through a simple molding process, or through a sophisticated rapid prototyping process, is disclosed. CCMC articles having regions of different composition and/or properties are also disclosed.

Abstract: A vacuum centrifugally cast combustion liner suitable for use in a gas turbine engine operating at temperatures ranging from ambient up to about 1700.degree. F. is provided. The combustion liner is formed by centrifugally vacuum casting a precipitation hardened nickel-based superalloy having controlled, low amounts of aluminum and titanium. The combustion liner is characterized by a homogeneous grain structure having enhanced strength and creep resistance particularly at elevated temperatures. In addition, the preferred elemental composition, particularly the relatively small amounts of aluminum and titanium, enhance the weldability and overall manufacturability of the combustion liner.

Abstract: A superalloy article is fabricated by casting a high melting temperature superalloy composition and then refurbishing the primary defects that are found in the surface of the cast piece. The article is refurbished by excising the primary defects and a surrounding portion of metal by grinding, filling the excised volume with metal of the same composition as the cast article by welding or a similar technique, smoothing the surface around any resulting filler metal defects, and applying a cladding powder to the surface from which the filler metal defects are removed. The cladding powder is applied by painting a binder onto the surface and then dusting cladding powder onto the binder before it has dried. The cladding powder is a mixture of particles of a high melting temperature superalloy and particles of a lower melting temperature metal. The article is heated to a preselected temperature, depending on the alloy, to melt and subsequently solidify the cladding powder.