With Destruction Of Pattern To Disassociate Patents (Class 164/34)
  • Patent number: 10639705
    Abstract: A method of fabricating a finished part includes generating or creating a master pattern using an additive manufacturing process, and the master pattern corresponds in shape to the finished part. A shell is created by applying one or more layers of one or more coating materials to the master pattern. The master pattern is then dissolved while the master pattern is in the shell to create a cavity in the shell that corresponds in shape to the finished part. A molten material is then poured into the cavity of the shell. The molten metal is allowed to cool and to harden and/or to reach a determined temperature such that the molten metal becomes the finished part. The shell is then removed from around the finished part.
    Type: Grant
    Filed: December 23, 2016
    Date of Patent: May 5, 2020
    Assignee: FISHER CONTROLS INTERNATIONAL LLC
    Inventor: Sam T. Fuccio
  • Patent number: 10596432
    Abstract: A golf club and golf club head having a high static loft angle, low forward center of gravity, and enhanced z-axis gear effect via a large roll radius and/or tightly controlled moment of inertia about the CG x-axis, Ixx, associated with upward and downward twisting of the club head.
    Type: Grant
    Filed: November 15, 2018
    Date of Patent: March 24, 2020
    Assignee: Taylor Made Golf Company, Inc.
    Inventors: Mark Vincent Greaney, Brandon H. Woolley
  • Patent number: 10563538
    Abstract: A machine includes a section that defines a target vibrational mode to dampen and a nanocellular foam damper that includes interconnected ligaments in a cellular structure. The interconnected ligaments have an average ligament size defined with respect to a vibrational loss modulus of the nanocellular foam damper and the target vibrational mode. Also disclosed is a method of damping vibration.
    Type: Grant
    Filed: October 21, 2014
    Date of Patent: February 18, 2020
    Assignee: UNITED TECHNOLOGIES CORPORATION
    Inventor: Michael J. Birnkrant
  • Patent number: 10557695
    Abstract: A skeletal composite material includes an internal skeleton structure surrounded by a matrix material. The skeleton structure and the matrix are made of different materials having different properties. It should be appreciated that the skeleton structure and the matrix can be made of any suitable material including metal, ceramic, carbon, polymers, or combinations of these materials. Preferably, the skeleton structure and/or the matrix are made primarily of metal or ceramic. The skeletal composite material can be made by filling a skeleton structure with powder, compacting the skeleton structure and powder to form a preform, and consolidating the preform to form the skeletal composite material.
    Type: Grant
    Filed: December 7, 2016
    Date of Patent: February 11, 2020
    Assignee: Amaranthine Resources, LLC
    Inventors: Henry S. Meeks, Jonathan Meeks
  • Patent number: 10533515
    Abstract: An intake-port core includes a body part having the same outer shape as that of the intake port, a port-injector part having the same outer shape as that of a port-injector insertion part, and an extending part. A cooling-water flow-passage core includes a water-jacket core having the same outer shape as that of a water jacket. The intake-port core is inserted from the extending part thereof into the water-jacket core so as to join the cooling-water flow-passage core to the intake-port core. Thereafter, a core print part that is a separate body from the intake-port core is joined to the intake-port core.
    Type: Grant
    Filed: February 21, 2017
    Date of Patent: January 14, 2020
    Assignee: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Yusei Kusaka, Kazuya Mikashima, Hiroyuki Ikuta
  • Patent number: 10451356
    Abstract: A lost wax cast vapor chamber device is provided. Once a mesh is produced, a meltable core is formed from a meltable core material with the mesh positioned at least partially inside the core. Over the meltable core a metallic layer is formed, at least partially surrounding the meltable core. A chamber formed by the metallic layer is exposed by melting the meltable core to cause it to be removed from an internal void of the chamber, the internal void encapsulating the mesh. The melted material from the meltable core flows out an opening on at least one surface of the chamber. Subsequently, the internal void is filled at least partially with a working fluid and the opening is closed. The mesh supports the surfaces of the chamber against deformation under the vacuum of the internal void. Movement of working fluid by capillary action is facilitated by the mesh.
    Type: Grant
    Filed: December 8, 2016
    Date of Patent: October 22, 2019
    Assignee: MICROSOFT TECHNOLOGY LICENSING, LLC
    Inventors: Jeffrey Taylor Stellman, Kurt Allen Jenkins, Lincoln M. Ghioni, Andrew Douglas Delano
  • Patent number: 10363600
    Abstract: A mold assembly for rotating electrical machines housings, the mold having part of the cooling duct geometry on its side portion and another portion on the center mold, in order to eliminate the requirement of casting plugs. A rotating electrical machine housing manufactured from the mold assembly.
    Type: Grant
    Filed: July 22, 2014
    Date of Patent: July 30, 2019
    Assignee: WEG Equipamentos Elétricos S.A.
    Inventor: Jose Roberto Dos Santos
  • Patent number: 10363634
    Abstract: A method for forming a metallic structure having a non-linear aperture includes providing a main tool having a formation surface corresponding to a desired structure shape of the metallic structure. The method also includes attaching a removable tool having a shape corresponding to a desired aperture shape of the non-linear aperture to the main tool. The method also includes depositing a layer of material on the formation surface using a cold-spray technique. The method also includes removing the removable tool from the layer of material such that the layer of material defines the non-linear aperture.
    Type: Grant
    Filed: December 22, 2016
    Date of Patent: July 30, 2019
    Assignee: UNITED TECHNOLOGIES CORPORATION
    Inventors: Gary D. Roberge, William J. Brindley
  • Patent number: 10207314
    Abstract: An investment mold includes a mold cavity and a refractory investment wall that bounds at least a portion of the mold cavity. At least a portion of the refractory investment wall includes a plurality of fugitive beads. The fugitive beads can be sacrificed to provide voids that control the strength of the refractory investment wall such that the wall fractures at the voids during investment casting to alleviate stress on a solidified metal cast in the mold cavity.
    Type: Grant
    Filed: January 27, 2014
    Date of Patent: February 19, 2019
    Assignee: UNITED TECHNOLOGIES CORPORATION
    Inventors: Mario Bochiechio, Charles R. Watson
  • Patent number: 10099274
    Abstract: In the following expression, it is assumed that a thickness of a coating agent applied to a foam pattern [2] is t (mm), a diameter of a hole part [3] is D (mm), and a normal-temperature transverse strength of the dried coating agent is ?c (MPa). At the time of producing a casting provided with a hole having a diameter of 18 mm or smaller and a length of 1 (mm), a coating agent that satisfies the following expression is used when a solidification end time te (sec) at which solidification of a melt ends on a periphery of the hole part [3] is within a time t0 (sec) at which thermal decomposition of the coating agent ends. ?c?{t0/(t0?te)}×(1.
    Type: Grant
    Filed: October 21, 2015
    Date of Patent: October 16, 2018
    Assignee: Kobe Steel, Ltd.
    Inventor: Kazuyuki Tsutsumi
  • Patent number: 10076923
    Abstract: A print on-demand color shift material which has high reflection, high saturation color and intrinsic, high impact color-shift produced by thermal printing or laser writing for use, for example in security laminates, tax and excise stamps, machine-readable features and banknote foils, and offering a rainbow of colors with full color shifting, producible in full manufacturing scale.
    Type: Grant
    Filed: January 29, 2015
    Date of Patent: September 18, 2018
    Assignee: OPALUX INCORPORATED
    Inventors: Andre Arsenault, Romain Perrier-Cornet
  • Patent number: 10058400
    Abstract: A green metal body includes metal particles and a binder in the shape of an orthodontic bracket and/or base plate. The green metal body is fabricated by being laser-cut with a laser to shape the green metal body into the shape of an orthodontic bracket and/or to carve recesses and/or undercuts into the bonding surface of the bracket. The green metal body is sintered to shrink its volume into a denser and less porous sintered metal body configured to be an orthodontic bracket. The resultant sintered orthodontic bracket includes recesses and/or undercuts in the bonding surface to provide a mechanical aspect when bonded to a tooth.
    Type: Grant
    Filed: July 28, 2015
    Date of Patent: August 28, 2018
    Assignee: Ormco Corporation
    Inventors: Norbert Abels, Claus H. Backes
  • Patent number: 9862022
    Abstract: Provided is a casting method using lost foam capable of forming a small highly-finished hole with a diameter of 18 mm or less and a length of 50 mm or more by casting. A casting method using lost foam of the present embodiment includes the steps of embedding, in foundry sand, a casting pattern formed by applying a mold wash with a thickness of 1 mm or more to a surface of the foam pattern, the foam pattern having a hole with a diameter of D (mm); replacing the foam pattern with molten metal by pouring the molten metal into the casting pattern and losing the foam pattern; and forming a casting having a small hole with a diameter of 18 mm or less and a length of 50 mm or more by cooling the molten metal, and the method satisfies the following formulas (0) and (1): 2<D?19.7??Formula (0) ?c??0.36+140/D2??Formula (1) where ?c (MPa) is transverse rupture strength (bending strength) of the mold wash that is heated to decompose resin constituting the mold wash and then returned to room temperature.
    Type: Grant
    Filed: August 5, 2015
    Date of Patent: January 9, 2018
    Assignee: Kobe Steel, Ltd
    Inventors: Kazuyuki Tsutsumi, Yusaku Takagawa
  • Patent number: 9843236
    Abstract: A heat exchange system for casings of rotary electric machines is described herein. The heat exchange system applied to the rotating electrical machine casing and the machine is equipped with a finned casing comprising a number of fins equipped with a modified profile, each one interleaved with complementary fins, both profiles distributed over the external surface of the casing. The fins have a predominantly continuous profile, supported in parallel along the casing height, and respectively show projections from a guideline, with structures with trapezoidal or rectangular section being interleaved to one another in a front region of the machine.
    Type: Grant
    Filed: December 21, 2012
    Date of Patent: December 12, 2017
    Assignee: WEG Equipamentos Eletricos S.A.-Motores
    Inventor: Cassiano Antunes Cezario
  • Patent number: 9833834
    Abstract: A blade preform includes a strut connecting a plat-form to a blade root portion extending longitudinally in an upstream-downstream direction, an upstream web and a downstream web, which each extend in a direction substantially perpendicular to the longitudinal direction of the blade root and are formed at the upstream and downstream ends of the strut. The upstream and downstream webs connect the upstream and downstream ends of the plat-form to the upstream and downstream ends of the blade root. The blade root extends in a direction perpendicular to the longitudinal direction of the blade root over a distance smaller than that of the upstream and downstream webs and the side edges of each web are extended by walls that converge at the flanks of the blade root.
    Type: Grant
    Filed: June 4, 2014
    Date of Patent: December 5, 2017
    Assignee: SNECMA
    Inventors: Sébastien Serge Francis Congratel, Raphaël Jean Philippe Dupeyre, Guillaume Klein, David Mathieu, Ba-Phuc Tang
  • Patent number: 9737930
    Abstract: A method to manufacture reticulated metal foam via a dual investment, includes pre-investment of a precursor with a diluted pre-investment ceramic plaster then applying an outer mold to the encapsulated precursor as a shell-mold.
    Type: Grant
    Filed: December 7, 2015
    Date of Patent: August 22, 2017
    Assignee: United Technologies Corporation
    Inventors: Ryan C Breneman, Steven J Bullied, David R Scott
  • Patent number: 9683443
    Abstract: A method for making a gas turbine engine ceramic matrix composite airfoil is disclosed. The method includes fabricating an airfoil preform that has a slotted forward end and a continuous trailing end. The slotted forward end of the airfoil preform is coupled to an airfoil core insert. A ceramic matrix composite covering is applied to cover the slots of the airfoil perform. The continuous trailing end of the airfoil preform is removed to expose the slots. A gas turbine engine airfoil is also disclosed.
    Type: Grant
    Filed: December 26, 2013
    Date of Patent: June 20, 2017
    Assignee: Rolls-Royce North American Technologies, Inc.
    Inventors: Ted J. Freeman, Richard C. Uskert
  • Patent number: 9616492
    Abstract: A ceramic mixture is shaped to form a ceramic core having a configuration which corresponds to the configuration of a cavity in an airfoil. The ceramic core is positioned between a plurality of arrays of burners. Flames from the burners burn organic material contained in the ceramic core. During burning of the organic material, the core is upright with a longitudinal central axis of the core in a generally vertical orientation. The ceramic core may be dipped in a ceramic material after having performed the step of burning organic material and prior to additional heat treatment of the ceramic core.
    Type: Grant
    Filed: September 16, 2014
    Date of Patent: April 11, 2017
    Assignee: PCC Airfoils, Inc.
    Inventors: Anthony Vecchio, Luke Rodgers, Jack Guritza
  • Patent number: 9555470
    Abstract: Certain exemplary embodiments can provide a system, machine, device, manufacture, and/or composition of matter configured for and/or resulting from, and/or a method for, activities that can comprise and/or relate to, investment casting a product in a mold, the product comprising at least one wall, the mold comprising a core, an inner primary shell, and an outer secondary shell.
    Type: Grant
    Filed: June 9, 2016
    Date of Patent: January 31, 2017
    Assignee: Mikro Systems, Inc.
    Inventors: Benjamin Heneveld, John R. Paulus, Jon T. Moore
  • Patent number: 9505055
    Abstract: A method for removing a part from a mold and to a machine for molding the part, the part made of a material having a glass-transition temperature and a melting temperature that is higher than the glass-transition temperature, and which is shaped in the cavity of a mold, includes at least two mold portions defining the shaping cavity therebetween. The mold is at a temperature between the glass-transition temperature and the melting temperature. The method includes opening the mold by spacing apart the mold portions, locally spraying a cooling gas toward the part remaining in a portion of the mold using at least one nozzle, and, after a predetermined time period following the start of spraying the gas, ejecting the part from the portion of the mold, the time period being such that the part reaches a temperature that is lower than the glass-transition temperature thereof.
    Type: Grant
    Filed: June 1, 2012
    Date of Patent: November 29, 2016
    Assignees: UNIVERSITE JOSEPH FOURIER, INSTITUT POLYTECHNIQUE DE GRENOBLE, CENTRE NATIONAL DE LA RECHERCHE SCIENTIFIQUE (CNRS)
    Inventors: Sébastien Gravier, Georges Kapelski, Jean-Jacques Blandin, Charles Josserond
  • Patent number: 9387533
    Abstract: Certain exemplary embodiments can provide a system, machine, device, manufacture, and/or composition of matter configured for and/or resulting from, and/or a method for, activities that can comprise and/or relate to, investment casting a product in a mold, the product comprising at least one wall, the mold comprising a core, an inner primary shell, and an outer secondary shell.
    Type: Grant
    Filed: September 29, 2015
    Date of Patent: July 12, 2016
    Assignee: Mikro Systems, Inc.
    Inventors: Benjamin Heneveld, John R. Paulus, Jon T. Moore
  • Patent number: 9068275
    Abstract: A grain starter for use in solidification of molten metallic material forming an article having a directional grain structure and a method for solidifying an article having a directional grain structure with a substantial absence of stray grains. The grain starter comprises a grain-starting material that initiates grain growth in the molten metallic material in a preselected crystallographic direction. The grain-starting material has a melting temperature higher than the metallic material forming the article lest the grain starter be modified by contact with the molten material. The grain starter further includes a feature that modifies heat transfer characteristics of the metallic material in contact with it in order to produce an article having grains oriented in the preselected crystallographic orientation and modifies the profile of the advancing solidification front. The article is substantially free of stray grains not oriented in the preselected crystallographic direction.
    Type: Grant
    Filed: May 8, 2013
    Date of Patent: June 30, 2015
    Assignee: General Electric Company
    Inventors: Shan Liu, Warren Tan King, Srinivasan Raghavan, Arthur S. Peck, Dayananda Narayana
  • Publication number: 20150147186
    Abstract: The disclosure relates generally to mold compositions and methods of molding and the articles so molded. More specifically, the disclosure relates to silicon carbide-containing mold compositions, silicon carbide-containing intrinsic facecoat compositions, and methods for casting titanium-containing articles, and the titanium-containing articles so molded.
    Type: Application
    Filed: November 26, 2013
    Publication date: May 28, 2015
    Applicant: GENERAL ELECTRIC COMPANY
    Inventors: Bernard Patrick BEWLAY, Joan MCKIEVER, Brian Michael ELLIS, Nicholas Vincent MCCLASKY
  • Publication number: 20150136350
    Abstract: The object of the present invention is to provide an embedding material composition for casting that makes it possible to conduct a favorable casting in the case where casting is conducted using a resin pattern that is different from a conventional wax pattern in disappearance temperature and disappearance behaviors through “rapid heating” excellent in treatment efficiency. The present invention relates to an embedding material composition for casting not using a heat-expandable refractory material as a main component, comprising: a binder; and a non-heat-expandable refractory material having an average particle diameter of 5 to 20 ?m as main components, in which a content of the binder is 25 to 40 parts by mass and a content of the non-heat-expandable refractory material is 60 to 75 parts by mass in the case where the total amount of the main components is 100 parts by mass, and the present invention also relates to a casting process using the embedding material composition for casting.
    Type: Application
    Filed: June 17, 2013
    Publication date: May 21, 2015
    Applicant: Yoshino Gypsum Co., Ltd.
    Inventors: Emi Mamada, Kenichi Sugano, Masato Yoshikane
  • Publication number: 20150139850
    Abstract: A method of casting a low alloy steel using a mold is disclosed. The method includes receiving the mold having a foam pattern disposed within a sand casing. The received foam pattern is coated with a permeable refractory coating and is disposed between compacted sand and the sand casing. The method further includes pouring a molten metal comprising a low alloy steel having a carbon content in a range from about 0.1 to about 0.4 percent into the mold so as to vaporize the foam pattern and remove gasification products through the permeable refractory coating, to form a low alloy steel casting. Further, the method includes removing the low alloy steel casting from the mold.
    Type: Application
    Filed: November 15, 2013
    Publication date: May 21, 2015
    Applicant: General Electric Company
    Inventors: Qi Zhao, Steven Robert Hayashi, Brian Victor Moore, Daniel Tribeni Persaud, Michael Douglas Arnett, Junyoung Park
  • Publication number: 20150129150
    Abstract: Various embodiments include methods and related systems for laser-assisted casting. Some embodiments include a method including: performing laser ablation to a preliminary wax casting model to form a modified wax model including at least one additional feature absent from the wax casting substrate; coating the modified wax model to form a mold shape around the modified wax model; and removing the modified wax model to leave a casting mold including the at least one additional feature.
    Type: Application
    Filed: November 8, 2013
    Publication date: May 14, 2015
    Applicant: General Electric Company
    Inventor: Zhaoli Hu
  • Publication number: 20150129151
    Abstract: Various embodiments include methods and related systems for laser-assisted casting. Some embodiments include a method including: performing laser ablation to a preliminary wax casting model to form a modified wax model including at least one surface texture element absent from the wax casting substrate; coating the modified wax model to form a mold shape around the modified wax model; and removing the modified wax model to leave a casting mold including the at least one surface texture element.
    Type: Application
    Filed: November 8, 2013
    Publication date: May 14, 2015
    Applicant: General Electric Company
    Inventor: Zhaoli Hu
  • Publication number: 20150129152
    Abstract: Various embodiments include methods and related systems for laser-assisted casting. Some embodiments include a method including: performing laser ablation to a preliminary wax casting model to form a modified wax model including at least one cooling hole absent from the wax casting substrate; coating the modified wax model to form a mold shape around the modified wax model; and removing the modified wax model to leave a casting mold including the at least one cooling hole.
    Type: Application
    Filed: November 8, 2013
    Publication date: May 14, 2015
    Applicant: General Electric Company
    Inventor: Zhaoli Hu
  • Patent number: 8997836
    Abstract: A multi-wall ceramic core for casting an airfoil with one or more internal cooling passages is made by preforming at least one fugitive core insert to have a joint-forming surface with a male and/or female joint feature and then forming at least one fugitive core insert in-situ adjacent and integrally connected and fused to the at least one preformed core insert at the joint-forming surface to form an interlocked, fused joint to form a composite core insert that includes features to form internal passage surfaces in the core when the composite core insert is removed. Another aspect involves preforming first and second fugitive core inserts to have respective joint-forming surfaces with respective snap-fittable joint features and assembling the first and second fugitive core inserts to form a composite core insert by snap fitting the snap-fittable joint features together to form an interlocked joint.
    Type: Grant
    Filed: October 21, 2014
    Date of Patent: April 7, 2015
    Assignee: Howmet Corporation
    Inventors: Boyd A. Mueller, Darren K. Rogers, Timothy J. Molamphy
  • Publication number: 20150078958
    Abstract: The disclosure relates generally to core compositions and methods of molding and the articles so molded. More specifically, the disclosure relates to core compositions and methods for casting hollow titanium-containing articles, and the hollow titanium-containing articles so molded.
    Type: Application
    Filed: September 18, 2013
    Publication date: March 19, 2015
    Applicant: GENERAL ELECTRIC COMPANY
    Inventors: Bernard Patrick BEWLAY, Joan MCKIEVER, Brian Michael ELLIS, Nicholas Vincent MCLASKY
  • Patent number: 8967229
    Abstract: An evaporative pattern casting method is taught which does not reduce accuracy of an evaporative pattern. The evaporative pattern casting method comprises a part manufacturing process (S2), an assembly process (S4), a sand mold manufacturing process (S6), a molten metal pouring process (S8) and a sand removal process (S12). In the part manufacturing process, the evaporative pattern is manufactured as a plurality of separate parts. In the assembly process, the parts are assembled on a work plane. In the sand mold manufacturing process, the evaporative pattern is covered with sand to form a sand mold without moving the assembled evaporative pattern from the work plane. In the molten metal pouring process, molten metal is poured into the sand mold. In the sand removal process, the sand is removed after the molten metal has solidified.
    Type: Grant
    Filed: January 28, 2011
    Date of Patent: March 3, 2015
    Assignee: Toyota Jidosha Kabushiki Kaisha
    Inventors: Susumu Okabe, Masanori Sato, Masashi Takahashi, Tsuyoshi Nanba
  • Patent number: 8936066
    Abstract: A method of using a bonded refractory mold is disclosed. The method includes forming a refractory mold including a mold wall on a fugitive pattern including a thermally removable material. The mold wall including a refractory material and defining a sprue, a gate and a mold cavity, the gate having a gate inlet opening into the sprue and a gate outlet opening into the mold cavity; a gas vent extending through the mold wall; and a gas permeable refractory material covering the gas vent, the fugitive pattern having a sprue portion, the sprue portion having a sprue channel that is in fluid communication with a sprue inlet and that extends toward a sprue outlet. The method also includes heating the refractory mold with a hot gas to remove the thermally removable material, wherein a portion of the hot gas is exhausted from the refractory mold through the gas vent.
    Type: Grant
    Filed: March 15, 2013
    Date of Patent: January 20, 2015
    Assignee: Metal Casting Technology, Inc.
    Inventor: Attila P. Farkas
  • Patent number: 8936068
    Abstract: A method of casting a component (42) having convoluted interior passageways (44). A desired three dimensional structure corresponding to a later-formed metal alloy component is formed by stacking a plurality of sheets (18, 20) of a fugitive material. The sheets contain void areas (22) corresponding to a desired interior passageway in the metal alloy component. A ceramic slurry material is cast into the three dimensional structure to form either a ceramic core (34) or a complete ceramic casting vessel (38). If just a ceramic core is formed, a wax pattern is formed around the ceramic core and an exterior ceramic shell (38) is formed around the wax pattern by a dipping process prior to the removal of the fugitive material and wax. An alloy component having the desired interior passageway is cast into the casting vessel after the fugitive material is removed.
    Type: Grant
    Filed: April 15, 2011
    Date of Patent: January 20, 2015
    Assignees: Siemens Energy, Inc., Mikro Systems, Inc.
    Inventors: Ching-Pang Lee, Gary B. Merrill, Andrew J. Burns
  • Patent number: 8915289
    Abstract: A multi-wall ceramic core for casting an airfoil with one or more internal cooling passages is made by preforming at least one fugitive core insert to have a joint-forming surface with a male and/or female joint feature and then forming at least one fugitive core insert in-situ adjacent and integrally connected and fused to the at least one preformed core insert at the joint-forming surface to form an interlocked, fused joint to form a composite core insert that includes features to form internal passage surfaces in the core when the composite core insert is removed. Another aspect involves preforming first and second fugitive core inserts to have respective joint-forming surfaces with respective snap-fittable joint features and assembling the first and second fugitive core inserts to form a composite core insert by snap fitting the snap-fittable joint features together to form an interlocked joint.
    Type: Grant
    Filed: March 13, 2013
    Date of Patent: December 23, 2014
    Assignee: Howmet Corporation
    Inventors: Boyd A. Mueller, Darren K. Rogers, Timothy J. Molamphy
  • Patent number: 8899303
    Abstract: A multi-wall ceramic core for casting an airfoil with one or more internal cooling passages is made by preforming at least one fugitive core insert, then forming at least one core insert in-situ adjacent and fused to the at least one preformed core insert by introducing fluid fugitive pattern material into a composite core insert mold whereby the fugitive core inserts are integrally connected as a single composite core insert that includes features to form internal passage surfaces in the core when the composite core insert is removed. The composite core insert is placed in a core molding die cavity, and a fluid ceramic material is introduced into the die cavity to form the ceramic core body incorporating the fugitive composite core insert therein.
    Type: Grant
    Filed: May 10, 2011
    Date of Patent: December 2, 2014
    Assignee: Howmet Corporation
    Inventors: Boyd Mueller, Darren Rogers, Timothy J. Molamphy
  • Patent number: 8893767
    Abstract: A multi-wall ceramic core for casting an airfoil with one or more internal cooling passages is made by preforming at least one fugitive core insert, then forming at least one core insert in-situ adjacent and fused to the at least one preformed core insert by introducing fluid fugitive pattern material into a composite core insert mold whereby the fugitive core inserts are integrally connected as a single composite core insert that includes features to form internal passage surfaces in the core when the composite core insert is removed. The composite core insert is placed in a core molding die cavity, and a fluid ceramic material is introduced into the die cavity to form the ceramic core body incorporating the fugitive composite core insert therein.
    Type: Grant
    Filed: September 19, 2012
    Date of Patent: November 25, 2014
    Assignee: Howmet Corporation
    Inventors: Boyd Mueller, Darren Rogers, Timothy J. Molamphy
  • Publication number: 20140290892
    Abstract: Refractory slurry for use in coating a foam cluster to provide a foam pattern for lost foam casting is provided. The slurry includes a catalyst capable of catalyzing reactions for vaporizing the foam cluster. A foam pattern with a refractory coating including the catalyst and processes for preparing the foam pattern and using the foam pattern are also provided.
    Type: Application
    Filed: March 24, 2014
    Publication date: October 2, 2014
    Applicant: General Electric Company
    Inventors: Zhaoping WU, Brian Victor MOORE, Michael Douglas ARNETT, Dejia WANG, Junyoung PARK, Yanfei GU, Qi ZHAO
  • Publication number: 20140262107
    Abstract: A refractory mold is disclosed. The refractory mold includes a fugitive pattern assembly comprising a hollow sprue that comprises a sprue wall disposed about a longitudinal axis; a pattern disposed outwardly of the sprue wall; and an outwardly extending gate attached to and extending between the sprue wall and the pattern, the hollow sprue, pattern and gate each formed from a fugitive material; and a refractory mold formed on and having a mold cavity defined by an outer surface of the fugitive pattern assembly.
    Type: Application
    Filed: March 14, 2013
    Publication date: September 18, 2014
    Applicant: HITCHINER MANUFACTURING CO., INC.
    Inventors: Michael R. Hanrahan, Skip L. Patteuw
  • Publication number: 20140190650
    Abstract: A prefabricated sprue assembly provides attachment to independently-produced investment casting molds to substantially reduce the need for pattern material. Installable connections between the prefabricated sprue assembly and the investment mold allow substantial reduction of scrap loss caused by errors in production of individual investment molds by culling defective molds before installation to the sprue assembly.
    Type: Application
    Filed: January 7, 2013
    Publication date: July 10, 2014
    Applicant: WiSys Technology Foundation, Inc.
    Inventors: Daniel Scott McGuire, Eric Emst Hellstrom
  • Patent number: 8733421
    Abstract: An evaporative pattern casting process includes forming a mold by burying a pattern made of resin foam in casting sand, pouring molten metal into the mold, and evaporating the pattern with the molten metal and thereby casting a product. In the evaporative pattern casting process, casting time during founding is set according to a modulus (pattern volume÷pattern surface area) of the pattern. Accordingly, the casting time in the evaporative pattern casting process is accurately set with high precision.
    Type: Grant
    Filed: November 25, 2010
    Date of Patent: May 27, 2014
    Assignee: Honda Motor Co., Ltd.
    Inventors: Fumio Hirai, Osami Ito, Hiroyuki Yamada, Hiroshi Ichikawa, Hidetaka Hokazono, Tomohiko Yamamoto, Kosuke Murai
  • Publication number: 20140102656
    Abstract: A casting core assembly includes a metallic core and a ceramic core. A protuberant portion of a metallic core is received in a compartment of the ceramic core.
    Type: Application
    Filed: October 12, 2012
    Publication date: April 17, 2014
    Applicant: UNITED TECHNOLOGIES CORPORATION
    Inventors: Tracy A Propheter-Hinckley, Eric A Hansen
  • Patent number: 8678071
    Abstract: A lightweight metal mold having a necessary rigidity is realized. Firstly, an original pattern of an evaporative pattern is formed by machining an evaporative material block. The original pattern includes a three-dimensional mesh structure including a plurality of bar-shaped parts and connecting points that connect ends of the bar-shaped parts and are distributed in a three-dimensional space, and a plurality of block parts having fixed relative positional relationship by being fixed to the three-dimensional mesh structure. Then, at least a portion of at least one or more of the bar-shaped parts composing the original pattern is removed, and replaced with a tube member. Then, a full-mold casting is performed by using the evaporative pattern having the replaced tube member. Positional relationship of the block parts in which surfaces, etc. necessary for the metal mold are formed is fixed by the three-dimensional mesh structure, and the necessary rigidity is secured.
    Type: Grant
    Filed: January 28, 2011
    Date of Patent: March 25, 2014
    Assignee: Toyota Jidosha Kabushiki Kaisha
    Inventors: Hirotake Sueta, Kiyoshi Kameyama, Atsushi Takemoto, Tatsuya Watarai, Hitoshi Akimoto, Masaki Yamashita
  • Publication number: 20140079582
    Abstract: We describe a lattice part made of metal and a method for producing a lattice part made of metal or a metal alloy. The lattice has a thickness of less than 1 mm at a size of the gaps of less than 50 mm2. The lattice (5) comprises a connection made of knots, and perpendicular to the lattice surface has lattice bars and lattice knots of the same thickness. A method for the production of a lattice part made of metal, particularly made of light alloy, is characterized by a primary shaping process according to DIN 8580, wherein a mold is formed in the first step, a primary material is introduced in the mold cavity in the second step, the part is removed from the mold in the third step, and the finishing of the metallic lattice part is carried out in the fourth step.
    Type: Application
    Filed: November 19, 2013
    Publication date: March 20, 2014
    Applicant: AIT AUSTRIAN INSTITUTE OF TECHNOLOGY GMBH
    Inventors: RUDOLF ZAUNER, FRANZ RIEMELMOSER, MANFRED BAMMER
  • Patent number: 8622113
    Abstract: A method and apparatus for directionally controlled rapid solidification of a molten metal casting provides modified mold flasks containing mold media defining a mold cavity into which molten metal is poured and thereafter solidified. The mold media is fluid permeable and electrically and thermally conductive so that coolants passing through the media conduct heat away from the molten metal to promote solidification. Apparatus carried upon and within the mold flask allow controlled application of coolants to dissipate heat in a controlled manner to promote solidification in a controlled direction. Ports defined in the flasks, spaces between the mold media particulates and coolant, directionally applied by a movable cooling ring provide controlled directional cooling and castings having improved mechanical characteristics, with greater speed and increased efficiency.
    Type: Grant
    Filed: September 16, 2012
    Date of Patent: January 7, 2014
    Inventor: Charles B. Rau, III
  • Publication number: 20130220570
    Abstract: A method comprising the use of additive manufacturing techniques for creating molds and pattern parts for subsequent use in the casting of die components and die shoes for use in die stamping processes.
    Type: Application
    Filed: February 29, 2012
    Publication date: August 29, 2013
    Applicant: Ford Motor Company
    Inventors: Harold P. Sears, James Todd Kloeb, Evangelos Liasi, Larry Edward Ellis, Ronald Hasenbusch, John Philips, Alan Lawrence Jacobson
  • Publication number: 20130108459
    Abstract: The disclosure relates generally to mold compositions and methods of molding and the articles so molded. More specifically, the disclosure relates to mold compositions and methods for casting titanium-containing articles, and the titanium-containing articles so molded.
    Type: Application
    Filed: October 28, 2011
    Publication date: May 2, 2013
    Applicant: GENERAL ELECTRIC COMPANY
    Inventor: Bernard Patrick BEWLAY
  • Patent number: 8424186
    Abstract: A method for manufacturing an electric machine, made up of a housing, a stator accommodated in the housing, which is formed from a stator body and stator windings, a rotor, which is supported in the housing so as to be rotatable about a rotor axis, and a bearing support fastened on the housing, includes a housing foam part manufactured from at least three individual foam parts and a housing cast blank manufactured using the housing foam part in accordance with a lost foam casting method. Individual foam parts are made up of a center disk having an essentially hollow-cylindrical design and forming an intermediate piece of a housing foam part, an annular disk having an essentially hollow-cylindrical design and forming another intermediate piece of the housing foam part, and a bearing support disk having an essentially cup-shaped design and forming an end of the housing foam part.
    Type: Grant
    Filed: June 10, 2009
    Date of Patent: April 23, 2013
    Assignee: Robert Bosch GmbH
    Inventors: Denis Kern, Andreas Herzberger
  • Publication number: 20120298321
    Abstract: A knuckle for a railway coupler system is made without internal voids or cores. Instead, external pockets are formed on the front face and tail portion surface to reduce weight. The knuckle is formed by investment casting, which permits a pulling face to be provided without a draft angle or parting line typical of a cast part. As a result of these innovations, the knuckle according to the invention has an improved fatigue life.
    Type: Application
    Filed: August 8, 2012
    Publication date: November 29, 2012
    Applicant: STRATO, INC.
    Inventor: Andrew Smyth
  • Patent number: 8215372
    Abstract: A method of making a casting is disclosed. At least one support member has at least one first portion and a plurality of second portions connected to a mold core. The mold core is positioned at least in part in a sealed interior volume of a negative mold. The first portion is positioned outside the interior volume. The second portions are positioned at least in part inside the interior volume. A consumable pattern material is introduced into the negative mold to create a consumable pattern. The support member is disposed at least in part outside the consumable pattern. The consumable pattern is removed from the negative mold. A shell is formed around the consumable pattern. A casting material is introduced into an interior of the shell to create a final casting. The support member is disposed at least in part outside the final casting. A mold core is also described.
    Type: Grant
    Filed: October 17, 2008
    Date of Patent: July 10, 2012
    Assignee: BRP US Inc.
    Inventor: Willie R. Anglin
  • Patent number: 8201610
    Abstract: Methods, systems and compositions for manufacturing downhole tools and downhole tool parts for drilling subterranean material are disclosed. A model having an external peripheral shape of a downhole tool or tool part is fabricated. Mold material is applied to an external periphery of the model. The mold material is permitted to harden to form a mold about the model. The model is eliminated and a composite matrix material is cast within the mold to form a finished downhole tool or tool part.
    Type: Grant
    Filed: June 5, 2009
    Date of Patent: June 19, 2012
    Assignee: Baker Hughes Incorporated
    Inventors: John H. Stevens, Jimmy W. Eason