Extracting Pattern In Liquid State Patents (Class 164/35)
  • Publication number: 20040055736
    Abstract: To prevent movement of a ceramic core in a ceramic shell for the investment casting of a turbine blade, the free end of the core has one or more pins embedded therein so that the pins project into both the core and the ceramic shell which is applied over a wax layer. After removal of the wax and firing of the shell, molten metal is cast in the space left by the wax between the core and the shell. After hardening of the metal, the outwardly projecting part of the pins are removed during the machining of the surfaces of the turbine blade blank.
    Type: Application
    Filed: August 7, 2003
    Publication date: March 25, 2004
    Applicant: DONCASTERS PRECISION CASTINGS-BOCHUM GMBH
    Inventors: Wilfried Schneiders, Theodor Schmitte, Jorn Grossmann
  • Patent number: 6691764
    Abstract: There is provided a method for producing a dental prosthesis comprising: obtaining three-dimensional digital data relating to a patient's dentition; designing a virtual prosthesis for the dentition using the three-dimensional digital data; transmitting digital data corresponding to the virtual prosthesis to an automated prototyping system; producing a prototype of the dental prosthesis with the automated prototyping system, the prototype made of a material that can be ablated; covering at least the prototype with a hardening material and removing the prototype from within said hardening material to produce a mold for the dental prosthesis; casting the dental prosthesis by filling the mold with a metal and removing the hardening material.
    Type: Grant
    Filed: September 3, 2002
    Date of Patent: February 17, 2004
    Assignee: Cynovad Inc.
    Inventors: Hugo Embert, Jean-Marc Perot
  • Patent number: 6675868
    Abstract: A machine for forming and fitting core support pins into wax (70) surrounding a core (68) prior to covering the wax (70) with a frit (76), includes one or more punch devices (30), (82) within its structure, so as to enable the forming of one or more indentations in each pin, intermediate its ends, thereby providing a designed weakness in the pin to cause it to more reliably follow slight relative movement which occurs between the pins and the part being cast, thus reducing stresses in the surface of the part.
    Type: Grant
    Filed: May 22, 2002
    Date of Patent: January 13, 2004
    Inventor: Alec G Dodd
  • Patent number: 6634410
    Abstract: A mold apparatus and method for creating designs on the interior of molds includes a resilient form with an exterior and an interior, with a design formed on the exterior. A rigid support member is removably attached to the interior of the resilient form. A mold pattern, conformed to removably receive the rigid support member and the resilient form in combination, completes the basic elements of the invention. In one aspect of the invention, a passageway in the rigid support member is provided for introducing a gas between the rigid support member and the resilient form. In another aspect of the invention, a vacuum application device is provided for applying a vacuum to the interior of the resilient form.
    Type: Grant
    Filed: August 28, 2001
    Date of Patent: October 21, 2003
    Inventors: John H. Wilson, Robert E. Wilson, John T. Wilson
  • Patent number: 6629556
    Abstract: A compressor wheel is re-designed to permit die inserts (20), which occupy the air passage and define the blades (4, 5) during a process of forming a wax pattern (21) of a compressor wheel, to be pulled without being impeded by the blades. This modified blade design enables the automated production of wax patterns (21) using simplified tooling. These wax patterns (21) can be used in a large-scale investment casting process, and produce an economical cast titanium compressor wheel which performs aerodynamically at high boost pressure/RPM. The compressor wheel improves low cycle fatigue, withstands high temperatures and temperature changes, and permits operation at high boost pressure ratio while, on the other hand, having low weight, low inertial drag, and high responsiveness.
    Type: Grant
    Filed: May 7, 2002
    Date of Patent: October 7, 2003
    Assignee: BorgWarner, Inc.
    Inventors: David M. Decker, Steven Roby
  • Patent number: 6626230
    Abstract: Method making a multi-wall ceramic core for use in casting airfoils, such as turbine blades and vanes, wherein a fugitive pattern is formed having multiple thin wall pattern elements providing internal wall-forming spaces of a final core, the pattern is placed in a core molding die cavity having a desired core configuration, a fluid ceramic material is introduced into the die cavity about the pattern and between the pattern elements to form a ceramic core, and the core is removed from the die cavity. The fugitive pattern is selectively removed from the core to provide a multi-wall green core. The green core then is fired to develop core strength for casting and used to form an investment casting mold for casting an airfoil.
    Type: Grant
    Filed: October 25, 2000
    Date of Patent: September 30, 2003
    Assignee: Howmet Research Corporation
    Inventors: Harry A. Woodrum, William E. Sikkenga
  • Publication number: 20030164230
    Abstract: Methods for making molding casts by a process typically referred to as “investment casting” using a novel composition is described. The composition is a phosphate bonded material that contains mono-ammonium phosphate (MAP), magnesium oxide and silica filler (quartz, cristobalite, or a mixture thereof). It has been discovered that controlling the amount and ratio of these components has a significant impact on gas permeability (porosity), set time, cast smoothness and cast softness. The most outstanding feature of the new investments is the short mold fabrication and processing time that they allow due to their high gas permeability. The investments can be placed in a burn out furnace while still wet and can be heated rapidly to the firing temperature. The casts can be broken by sandblasting the casts with glass beads. Molds made from the casts have smooth surfaces indicating that the casts are free of visible inclusions and other defects.
    Type: Application
    Filed: March 10, 2003
    Publication date: September 4, 2003
    Inventors: Rachel R. Pineda, Thomas C. Chadwick
  • Patent number: 6588485
    Abstract: Cost considerations have prevented the use of titanium compressor wheels (1) in automotive air boost devices. A hybrid process is disclosed, wherein a wax pattern used in the investment casting process is intentionally designed not to produce a final (net shape) compressor wheel, but rather, is designed to produce a near net shape pattern including filled in areas (10, 11) which must be subsequently machined or milled away to produce the desired non-pullable shape compressor wheel. Surprisingly, when forming a titanium compressor wheel using the hybrid or two-step process, the technical complexity of each step (pattern forming and machining) is substantially lower, distortion of the wax blades (4) during pattern casting is reduced, casting of titanium is simplified, the process allows itself to be fully automated, and the dimensional accuracy of the final product is greater than with conventional techniques.
    Type: Grant
    Filed: May 10, 2002
    Date of Patent: July 8, 2003
    Assignee: BorgWarner, Inc.
    Inventor: David Michael Decker
  • Publication number: 20030121636
    Abstract: A method of casting including forming a shell mold around a pattern fabricated from an expendable material and then removing the expendable material from the shell mold. The shell mold is located within a housing such that an inlet port of the shell mold communicates with an opening in the housing. A supporting material is provided and substantially fills an open volume between an external surface of the shell mold and an interior surface of the housing. A molten material is then pressure cast through the inlet port and into the shell mold. The invention includes a mold assembly and a casting system useful in practicing the disclosed method.
    Type: Application
    Filed: December 27, 2001
    Publication date: July 3, 2003
    Inventors: Gerald A. Gegel, David Weiss
  • Publication number: 20030116300
    Abstract: An apparatus and method for forming a hollow golf club head is disclosed. The apparatus includes a first mold cavity having depressions formed therein, a second mold cavity having a shape complementary to the exterior of the desired club head, a ceramic core, and wax injecting means. Each depression of the first mold cavity has a depth equal to a desired wall thickness of a corresponding portion of the club head. When the ceramic core is placed in the first mold cavity and wax is injected, wax protuberances, which correspond to the depressions, are formed about the ceramic core. The wax protuberances position the ceramic core in the second mold cavity, where wax is deposited over the majority of the ceramic core.
    Type: Application
    Filed: December 6, 2002
    Publication date: June 26, 2003
    Applicant: Callaway Golf Company
    Inventor: John Bramley
  • Publication number: 20030111203
    Abstract: A fugitive pattern of an article to be investment cast wherein the pattern includes a plurality of locator embossments disposed in an array to provide a datum reference system by which the pattern can be held and positioned by a manipulator, such as for example a gripper device to a computer controlled robotic device, for assembly with another component of the pattern assembly. The datum embossments are located on a portion of the pattern that will be removed from the final metallic casting made to replicate the pattern. The casting includes integral cast datum embossments thereon by which the casting can be held and positioned.
    Type: Application
    Filed: November 25, 2002
    Publication date: June 19, 2003
    Applicant: Howmet Research Corporation
    Inventor: Michael W. Mertins
  • Publication number: 20030098136
    Abstract: A process for the assembly of wax trees in which a wax runner is placed in a flat position and a wax pattern is located adjacent the wax runner. Both the wax runner pattern and the wax runner are heated and then are placed in contact with one another where heated. Then the wax pattern and the wax runner are separated slightly to form a fillet weld between the wax pattern and the wax runner. An apparatus is also provided which, by robotics, brings a multiplicity of wax patterns to a wax runner and which automatically heats both the wax patterns and the wax runner before simultaneously pressing both the wax pattern and the wax runner together. Once a wax tree assembly is completed a new wax runner replaces the wax runner that has been formed into a wax tree and additional wax runners are affixed in the same manner.
    Type: Application
    Filed: November 26, 2002
    Publication date: May 29, 2003
    Inventors: Richard Ludwig, Stephen Derby, Raymond H. Puffer, Bruce S. Phipps
  • Patent number: 6568455
    Abstract: A method for making personalized jewelry and the personalized product of this jewelry making method. The method includes digitally capturing the image of a person or other object. The image is saved as a digital profile and processed to create a numerical profile. The numerical profile includes prototyping machine instructions that cause a prototyping machine to produce a wax block that contains a replica of the scanned object. The wax block is placed in a warm bath so that an outer wax melts away and an inner wax of the scanned object remains. The wax replica is then used in a “lost wax process” to make a mold of the wax replica. The mold is then used in a casting process wherein the mold is injected with precious, semi-precious, or base metals to make a cast of the object. The finished product is a replica of the object with exacting features such as nose, eyes, ears, etc. Any cavity or flat surface can be colored with epoxies, resins, enamels, or decorated further to give color contrast.
    Type: Grant
    Filed: April 10, 2001
    Date of Patent: May 27, 2003
    Inventor: Robert M. Zieverink
  • Patent number: 6554052
    Abstract: There is provided a method or process for fabricating a hollow jewelry article which is hollowed or bored out to an arcuate estent of 200° or greater. In accordance with this process, a metal ring model is prepared comprising a solid shank and a metal plate supported along the internal perimeter of the shank and arcuately extending at least 200° therealong. A first metal mold is produced from the metal ring model having the external shape of the jewelry article to be manufactured. From this mold, a wax model of the jewelry article is produced which is first filed down and then cast in order to form a metal model of a core insert; the core insert, like the ring model, has a plate disposed along the perimeter of the shank. This core insert is used to produce a second metal mold. This second mold may then be used repeatedly in order to form a soluble wax core insert model which is then inserted into the cavity of the first mold in order to define the hollow region of the article.
    Type: Grant
    Filed: September 9, 2002
    Date of Patent: April 29, 2003
    Assignee: Unimold Cast, Ltd.
    Inventors: Ervant Hashimian, Garabed Ayvazian
  • Publication number: 20030075295
    Abstract: The present invention discloses a white gold composition consisting essentially of copper, silver, zinc, and manganese, and further consisting of small amounts of tin, cobalt, silicon/copper and boron/copper. More particularly, the white gold composition of the present invention discloses a white gold composition consisting essentially of about 36% to about 57% copper, about 10% silver, about 18.2% to about 24.2% zinc, about 14% to about 28.9% manganese, and the balance further consisting of about 1% tin, about 0.025% to about 0.03% cobalt, about 0.52% silicon/copper, and about 0.2% boron/copper. An objective of the present invention is to provide for methods and compositions of casting, fabricating and soldering white gold that does not incorporate nickel or palladium. The present invention also discloses no tarnish results when hydrogen is used as a catalyst to all compositions.
    Type: Application
    Filed: August 2, 2001
    Publication date: April 24, 2003
    Inventor: Keith Weinstein
  • Publication number: 20030056927
    Abstract: A casting includes a heat transfer surface having a plurality of cavities. The plurality of cavities include a density of at least about 25 cavities per square centimeter to about 1,100 cavities per square centimeter resulting in increased surface area and therefore enhanced heat transfer capability. Also disclosed is a mold for forming a pattern for molding the casting. The mold includes a surface defining a portion of a chamber to which are attached a plurality of particles having an average particle size in a range of about 300 microns to about 2,000 microns.
    Type: Application
    Filed: October 24, 2002
    Publication date: March 27, 2003
    Inventors: Ching Pang Lee, Wayne Charles Hasz, Nesim Abuaf, Robert Alan Johnson
  • Publication number: 20030041992
    Abstract: An investment casting or molding method comprises encasing a consumable pattern in a no-bake material that hardens without the application of heat. The encased pattern is then transformed to a fluid state and evacuated, thereby forming a mold cavity. Preferably, the pattern is coated with a refractory material prior to encasement, so that the resulting mold cavity is lined with the refractory material. Coating the pattern with one and only one layer of refractory material is preferred, resulting in a refractory coating that is not self-supporting. In another embodiment, a refractory-coated consumable pattern is located in a container, and a granular backing material is packed in the container around the coated pattern. The pattern is then transformed to a fluid state and evacuated to form a refractory-lined mold cavity in the container. The refractory coating again preferably comprises one and only one layer of refractory material, thereby resulting in a coating that is not self-supporting.
    Type: Application
    Filed: August 28, 2001
    Publication date: March 6, 2003
    Inventors: David M. Fee, Carl E. Fidler
  • Patent number: 6516864
    Abstract: A tool (40) has a ledge portion (46) and a cutting blade portion (50) for cutting a groove (24, 26, 28) in a wax model (32) for an article of jewelry. The groove is formed after the wax model is formed by mechanical removal of the wax, preferably by cutting with tool (40). The wax model and gems are then placed in an investment mold where the lost wax technique is used to form an article of jewelry with the gems set therein.
    Type: Grant
    Filed: April 6, 2001
    Date of Patent: February 11, 2003
    Inventors: Harout Ounjian, Avo Ounjian
  • Publication number: 20030015308
    Abstract: Method and apparatus for making a ceramic core or fugitive pattern for use in investment casting wherein a fluid ceramic core or pattern material is introduced into a molding cavity defined by cooperating dies, and at least a region of one or both of the dies is heated during filling of the molding cavity with the material and then cooled to a lower ejection temperature before removal of a ceramic core or pattern from the molding cavity.
    Type: Application
    Filed: July 23, 2001
    Publication date: January 23, 2003
    Inventors: Ken E. Fosaaen, Jeffery S. Smith, David R. Erny, Robert M. Shay, Nick G. Lirones
  • Patent number: 6505672
    Abstract: A fugitive pattern of an article to be investment cast wherein the pattern includes a plurality of locator embossments disposed in an array to provide a datum reference system by which the pattern can be held and positioned by a manipulator, such as for example a gripper device to a computer controlled robotic device, for assembly with another component of the pattern assembly. The datum embossments are located on a portion of the pattern that will be removed from the final metallic casting made to replicate the pattern. The casting includes integral cast datum embossments thereon by which the casting can be held and positioned.
    Type: Grant
    Filed: May 22, 2001
    Date of Patent: January 14, 2003
    Assignee: Howmet Research Corporation
    Inventor: Michael W. Mertins
  • Patent number: 6502622
    Abstract: A casting includes a heat tranfer surface having a pluality of cavities. The plurality of cavities includes a density of at least about 25 cavities per square centimeter to about 1,100 cavities per square centimeter resulting in increased surface area and therefore enhanced heat transfer capability. Also disclosed is a mold for forming a pattern for molding the casting. The mold includes a surface defining a portion of a chamber to which are attached a plurality of particles having an average particle size in a range of about 300 microns to about 2,000 microns.
    Type: Grant
    Filed: February 12, 2002
    Date of Patent: January 7, 2003
    Assignee: General Electric Company
    Inventors: Ching Pang Lee, Wayne Charles Hasz, Nesim Abuaf, Robert Alan Johnson
  • Patent number: 6493912
    Abstract: A method of producing stone set jewelry includes the step of forming at least one affixation groove within the stone to be set in the jewelry. A stone to be set with the present method should have an upper and a lower portion which is at least substantially entirely hidden from view when the upper portion of the stone is viewed. In accordance with the present method the affixation groove should be formed in the lower portion of the stone such that it too is hidden from view when the upper portion of the stone is viewed. A heat setting method is disclosed for improving the bond between the pavilion of the stone and the wax model used in the casting process. The method also includes the deposition of a mounting material within the affixation groove by applying a conventional casting method.
    Type: Grant
    Filed: July 6, 2000
    Date of Patent: December 17, 2002
    Assignee: China Diamond Production Company Limited
    Inventor: Nelson Chi-Kai Ho
  • Publication number: 20020185244
    Abstract: A compressor wheel is re-designed to permit die inserts (20), which occupy the air passage and define the blades (4, 5) during a process of forming a wax pattern (21) of a compressor wheel, to be pulled without being impeded by the blades. This modified blade design enables the automated production of wax patterns (21) using simplified tooling. These wax patterns (21) can be used in a large-scale investment casting process, and produce an economical cast titanium compressor wheel which performs aerodynamically at high boost pressure/RPM. The compressor wheel improves low cycle fatigue, withstands high temperatures and temperature changes, and permits operation at high boost pressure ratio while, on the other hand, having low weight, low inertial drag, and high responsiveness.
    Type: Application
    Filed: May 7, 2002
    Publication date: December 12, 2002
    Applicant: Examiner Thai Ba Trieu
    Inventors: David M. Decker, Steven Roby
  • Publication number: 20020174968
    Abstract: A fugitive pattern of an article to be investment cast wherein the pattern includes a plurality of locator embossments disposed in an array to provide a datum reference system by which the pattern can be held and positioned by a manipulator, such as for example a gripper device to a computer controlled robotic device, for assembly with another component of the pattern assembly. The datum embossments are located on a portion of the pattern that will be removed from the final metallic casting made to replicate the pattern. The casting includes integral cast datum embossments thereon by which the casting can be held and positioned.
    Type: Application
    Filed: May 22, 2001
    Publication date: November 28, 2002
    Inventor: Michael W. Mertins
  • Publication number: 20020174967
    Abstract: A casting includes a heat transfer surface having a plurality of cavities. The plurality of cavities include a density of at least about 25 cavities per square centimeter to about 1,100 cavities per square centimeter resulting in increased surface area and therefore enhanced heat transfer capability. Also disclosed is a mold for forming a pattern for molding the casting. The mold includes a surface defining a portion of a chamber to which are attached a plurality of particles having an average particle size in a range of about 300 microns to about 2,000 microns.
    Type: Application
    Filed: February 12, 2002
    Publication date: November 28, 2002
    Inventors: Ching Pang Lee, Wayne Charles Hasz, Nesim Abuaf, Robert Alan Johnson
  • Patent number: 6485553
    Abstract: A wax composition for use in investment casting having improved properties includes polyethylene terephthalate as a filler material. The amount of polyethylene terephthalate used in the wax composition ranges from about 5 to about 50 parts by weight of the total wax composition. The use of polyethylene terephthalate as the filler material is effective for controlling the expansion and contraction properties of the wax composition providing a high degree of dimensional accuracy. Polyethylene terephthalate is relatively inexpensive compared to other inert filler materials, does not react with the mold, allows the wax pattern to be readily removed from the mold with reduced tendencies for shell cracking and results in little or no appreciable ash residue upon firing.
    Type: Grant
    Filed: August 21, 2000
    Date of Patent: November 26, 2002
    Assignee: The Kindt-Collins Company
    Inventor: Paul A. Guinn
  • Patent number: 6467526
    Abstract: A method of molding a jewelry ring having a beveled or rounded inner diameter and a hollow portion in a vertical mold comprises utilizing a multi-piece plug and a soluble insert in a mold to define a mold cavity in the desired shape of the ring or a portion of the ring. A molten material is introduced into the mold cavity and upon hardening forms a ring replica which is removed from the mold by first removing the formed ring replica from the mold halves and then removing the ring replica from the multi-piece plug by separating the multi-piece plug into its individual pieces. The ring replica can be used to form jewelry rings by investment casting.
    Type: Grant
    Filed: October 23, 2000
    Date of Patent: October 22, 2002
    Assignee: I.B. Goodman Manufacturing Co., Inc.
    Inventor: Steven Cope
  • Publication number: 20020148589
    Abstract: Method and apparatus for providing a plurality of locator elements on a ceramic core involves placing a ceramic core in a die cavity of die, positioning a plurality of pins in the die cavity with each pin having a locator-forming cavity on an inner end facing a surface of the core, and introducing melted wax into each locator-forming cavity to form a plurality of locator elements on the surface of the core.
    Type: Application
    Filed: April 17, 2001
    Publication date: October 17, 2002
    Inventor: Michael Wayne Mertins
  • Publication number: 20020144798
    Abstract: A tool (40) has a ledge portion (46) and a cutting blade portion (50) for cutting a groove (24, 26, 28) in a wax model (32) for an article of jewelry. The groove is formed after the wax model is formed by mechanical removal of the wax, preferably by cutting with tool (40). The wax model and gems are then placed in an investment mold where the lost wax technique is used to form an article of jewelry with the gems set therein.
    Type: Application
    Filed: April 6, 2001
    Publication date: October 10, 2002
    Inventors: Harout Ounjian, Avo Ounjian
  • Patent number: 6460594
    Abstract: A method of forming a gold statuette of a three-dimensional object, e.g. a man, is disclosed as including the steps of (1) scanning the man with scanning means to obtain data on his contour and shape; (2) inputting the data into a computer; (3) based on the data inputted into the computer, displaying a virtual three-dimensional image of the man on a monitor of the computer; (4) providing an epoxy resin prototype of the man by a sculpturing machine controlled by the computer; (5) providing silicon rubber mould-halves on the basis of the epoxy resin prototype; (6) providing a wax prototype on the basis of the silicon rubber mould-halves; (7) casting gold onto the wax prototype; (8) removing the wax, in which the scanning means revolves around the man to scan his contour and shape.
    Type: Grant
    Filed: January 27, 1999
    Date of Patent: October 8, 2002
    Assignee: Hang Fung Jewellery Co., Ltd.
    Inventor: Sai Wing Lam
  • Publication number: 20020129916
    Abstract: A machine for forming and fitting core support pins into wax (70) surrounding a core (68) prior to covering the wax (70) with a frit (76), includes one or more punch devices (30), (82) within its structure, so as to enable the forming of one or more indentations in each pin, intermediate its ends, thereby providing a designed weakness in the pin to cause it to more reliably follow slight relative movement which occurs between the pins and the part being cast, thus reducing stresses in the surface of the part.
    Type: Application
    Filed: May 22, 2002
    Publication date: September 19, 2002
    Inventor: Alec G. Dodd
  • Publication number: 20020129924
    Abstract: The invention relates to a method for producing a cast part of a thermal turbo-machine by way of a known casting process. Between a model mold and a ceramic insert, projections are located on the ceramic insert, whereby the projections have an angle (&agr;, &bgr;) between the center line and the outer edge of the projections of less than 30°, and whereby the projections are used both for the fixation of the insert during the casting process and for the reduction of the notch factor inside the recesses created in the cast part.
    Type: Application
    Filed: November 26, 2001
    Publication date: September 19, 2002
    Inventors: Herbert Brandl, Alexander Hoffs, Roland Muecke, Sergej Riazantsev, Alexander Beeck
  • Patent number: 6446697
    Abstract: Method of rapidly making casting, comprising: designing a computer graphic model of the casting; sectioning the graphic model into graphic members which are at least one of blocks and slabs; carving a solid member for each of the graphic members, the solid members being (i) constituted of a meltable or evaporative solid material (i.e. wax or polystyrene), (ii) proportional to and enveloping its corresponding graphic member, and the carving being carried out by accessing two or more sides of each solid member to at least essentially duplicate the corresponding graphic member; forming a mold around the pattern, and casting metal within the mold while removing the pattern from such mold either by evaporation during pouring of the molten metal thereinto or by melting prior thereto.
    Type: Grant
    Filed: June 13, 1997
    Date of Patent: September 10, 2002
    Assignee: Ford Global Technologies, Inc.
    Inventors: Furqan Zafar Shaikh, Martin Andrew Brogley, Craig Edward Burch, Neal James Corey, Thomas John Heater, Gary Allan Vrsek
  • Patent number: 6435255
    Abstract: A fingerprint jewelry includes any jewelry with a person's fingerprints cast in relief onto its surface. It is made by pressing a finger on a sheet of pliable wax medium to imprint it with fingerprints in relief. In a first embodiment, the wax medium is comprised of a soft wax medium soft enough to be imprinted at room temperature. In a second embodiment, the wax medium is comprised of a soft wax medium supported on a hard wax medium. The imprinted wax medium is positioned in a hollow form. A mold is created around the wax medium by pouring a mold material into the hollow form. An oven is used to harden the mold material and melt away the wax to leave a mold cavity. Molten precious metal is cast into the mold cavity with a casting machine to produce a casting with the fingerprints in relief. The casting is freed by breaking the mold. Additional work may be performed on the casting to produce a finished piece of jewelry.
    Type: Grant
    Filed: August 10, 1999
    Date of Patent: August 20, 2002
    Inventor: Vahe Kaladjian
  • Patent number: 6435256
    Abstract: The invention relates to a method for producing a cooled cast part for a thermal turbo machine by using a known casting process. Between a wax model of the cast part and a ceramic core, a wax seal is applied by hand above a step, only on an additional shoulder. The material that is created during the casting process at this point by the shoulder and the wax seal can be ground off without causing rough areas on the step to form. This simplifies the welding or soldering of a cooling plate to the step.
    Type: Grant
    Filed: August 6, 2001
    Date of Patent: August 20, 2002
    Assignee: Alstom (Switzerland) Ltd
    Inventors: Gordon Anderson, Peter Marx, Shailendra Naik
  • Patent number: 6431253
    Abstract: When a waste wax composition containing a filler is treated so that the filler is recovered and thus reclaimed, almost all the impurities coming from the lost wax casting mold may be removed, thereby recovering and thus refining at a high purity, a filler of a lost wax composition. Crude reclaimed filler is first produced by dissolving and dispersing a waste wax composition in an organic solvent, and separating a dissolved wax phase from a solids/wax-containing fraction. The crude reclaimed filler is then dispersed in an aqueous alkaline solution, so as to dissolve and thus remove alkali-soluble impurities, followed by a water-washing process.
    Type: Grant
    Filed: December 4, 2001
    Date of Patent: August 13, 2002
    Assignee: Kawasaki Steel Techno-Research Corporation
    Inventor: Tsuneo Kinjo
  • Patent number: 6427759
    Abstract: An investment cast stainless steel article, such as a marine propeller, is composed of a stainless steel alloy containing from 14.5 to 15.2% chromium, 5.35% to 6.05% nickel and 1.0% to 1.5% silicon.
    Type: Grant
    Filed: June 1, 2000
    Date of Patent: August 6, 2002
    Assignee: Brunswick Corporation
    Inventors: Richard S. Bauer, Barry L. Riutta, Terrance M. Cleary, Raymond J. Donahue, Kevin R. Anderson
  • Patent number: 6382300
    Abstract: A casting includes a heat transfer surface having a plurality of cavities. The plurality of cavities include a density of at least about 25 cavities per square centimeter to about 1,100 cavities per square centimeter resulting in increased surface area and therefore enhanced heat transfer capability. Also disclosed is a mold for forming a pattern for molding the casting. The mold includes a surface defining a portion of a chamber to which are attached a plurality of particles having an average particle size in a range of about 300 microns to about 2,000 microns.
    Type: Grant
    Filed: May 24, 2001
    Date of Patent: May 7, 2002
    Assignee: General Electric Company
    Inventors: Ching Pang Lee, Wayne Charles Hasz, Nesim Abuaf, Robert Alan Johnson
  • Patent number: 6364001
    Abstract: An article, such as an airfoil, is cast by a lost wax investment casting process. The process includes providing a core having a configuration corresponding to the configuration of a space to be formed in the airfoil. The core is at least partially enclosed with a layer of wax. A portion of the layer of wax is removed from the core. The step of removing a portion of the layer of wax from the core includes heating a tubular member and melting a portion of the wax layer by engaging the wax layer with the heated tubular member. Molten wax is conducted away from the core through the heated tubular member. A mold is formed by at least partially coating the wax layer with mold material which extends across the core at the locations where the melted wax was conducted away from the core. The wax layer is removed to form a mold cavity which is filled with molten metal to cast the airfoil.
    Type: Grant
    Filed: August 15, 2000
    Date of Patent: April 2, 2002
    Assignee: PCC Airfoils, Inc.
    Inventor: Andrew Michael Cross
  • Publication number: 20020029863
    Abstract: The invention relates to a method for producing a cooled cast part (1) for a thermal turbo machine by using a known casting process. Between a wax model (10) of the cast part (1) and a ceramic core (6), a wax seal (8) is applied by hand above a step (7), only on an additional shoulder (9). The material that is created during the casting process at this point by the shoulder (9) and the wax seal (8) can be ground off without causing rough areas on the step (7) to form. This simplifies the welding or soldering of a cooling plate to the step (7).
    Type: Application
    Filed: August 6, 2001
    Publication date: March 14, 2002
    Inventors: Gordon Anderson, Peter Marx, Shailendra Naik
  • Patent number: 6352098
    Abstract: When a waste wax composition containing a filler is treated so that the filler is recovered and thus reclaimed, almost all the impurities coming from the lost wax casting mold may be removed, thereby recovering and thus refining at a high purity, a filler of a lost wax composition. Crude reclaimed filler is first produced by dissolving and dispersing a waste wax composition in an organic solvent, and separating a dissolved wax phase from a solids/wax-containing fraction. The crude reclaimed filler is then dispersed in an aqueous alkaline solution, so as to dissolve and thus remove alkali-soluble impurities, followed (or preceded) by dispersion in an acidic aqueous solution so as to dissolve and thus remove acid-soluble impurities.
    Type: Grant
    Filed: September 12, 2000
    Date of Patent: March 5, 2002
    Assignee: Kawasaki Steel Techno-Research Corporation
    Inventor: Tsuneo Kinjo
  • Patent number: 6330904
    Abstract: A microwave-based process for dental casting includes the use of microwave radiation to obtain burnout of a wax pattern from an investment mold. Phosphate-based, thermal investment materials have been found suitable for use in the process.
    Type: Grant
    Filed: February 17, 1999
    Date of Patent: December 18, 2001
    Assignee: Micro Electronics Group Inc.
    Inventors: Billy Wayne Drake, Doyle W. Hopkins
  • Patent number: 6302185
    Abstract: A casting includes a heat transfer surface having a plurality of cavities. The plurality of cavities include a density of at least about 25 cavities per square centimeter to about 1,100 cavities per square centimeter resulting in increased surface area and therefore enhanced heat transfer capability. A mold for forming a pattern for molding the casting includes a surface defining a portion of a chamber to which are attached a plurality of particles having an average particle size in a range of about 300 microns to about 2,000 microns.
    Type: Grant
    Filed: January 10, 2000
    Date of Patent: October 16, 2001
    Assignee: General Electric Company
    Inventors: Ching Pang Lee, Wayne Charles Hasz, Nesim Abuaf, Robert Alan Johnson
  • Patent number: 6298904
    Abstract: A vent-forming apparatus for use in metal casting comprises a gas-permeable membrane with a lead-in tube attached to one surface and a breather tube attached to the opposite surface. The vent-forming apparatus may be used to create independent vents in the walls of shell-type molds used in the ceramic shell casting process for lost wax casting of ferrous and non-ferrous alloys. These vents exhaust gasses in the mold cavity to the atmosphere. The vent-forming apparatus also may be used in solid mold investment casting methods or in any other casting method in which venting is desirable or necessary.
    Type: Grant
    Filed: October 27, 1998
    Date of Patent: October 9, 2001
    Inventor: Richard F. Polich
  • Publication number: 20010020525
    Abstract: A casting includes a heat transfer surface having a plurality of cavities. The plurality of cavities include a density of at least about 25 cavities per square centimeter to about 1,100 cavities per square centimeter resulting in increased surface area and therefore enhanced heat transfer capability. Also disclosed is a mold for forming a pattern for molding the casting. The mold includes a surface defining a portion of a chamber to which are attached a plurality of particles having an average particle size in a range of about 300 microns to about 2,000 microns.
    Type: Application
    Filed: May 24, 2001
    Publication date: September 13, 2001
    Inventors: Ching Pang Lee, Wayne Charles Hasz, Nesim Abuaf, Robert Alan Johnson
  • Patent number: 6283194
    Abstract: A process for producing structural elements, preferably prototypes, in which a “lost” model, i.e., positive model, of the structural element is produced in a first step and the model is subsequently cast with a molding compound to produce a negative mold. The mold is then used for manufacturing the structural element, preferably a prototype, by casting. The model is cast and/or filled with the molding compound in a plurality of successive steps and the position of the model relative to a reference plane is changed in each of the individual steps of casting or filling.
    Type: Grant
    Filed: January 12, 1999
    Date of Patent: September 4, 2001
    Assignee: Grunewald GmbH & Co. KG
    Inventors: Jörg Stefan Detering, Christian Grunewald
  • Publication number: 20010001980
    Abstract: A microwave-based process for dental casting includes the use of microwave radiation to obtain burnout of a wax pattern from an investment mold. Phosphate-based, thermal investment materials have been found suitable for use in the process.
    Type: Application
    Filed: February 17, 1999
    Publication date: May 31, 2001
    Inventors: BILLY WAYNE DRAKE, DOYLE W. HOPKINS
  • Patent number: 6209621
    Abstract: An implantable prosthesis having porous textured surface regions and methods for making the same provide improved prostheses and prosthesis manufacturing methods. The implantable prostheses contain one more bead preforms that are secured to the metallic prosthesis components during the casting process to form porous textured surface regions in desired areas of the prostheses.
    Type: Grant
    Filed: July 7, 1995
    Date of Patent: April 3, 2001
    Assignee: Depuy Orthopaedics, Inc.
    Inventor: Debra J. Treacy
  • Patent number: 6155330
    Abstract: A spray forming pattern of a first metal having a melting point at a first temperature is formed. The spray forming pattern has a surface defining a cavity that has the shape of a master pattern. Steel particles having a carbon content in the range of 0.01-0.9% by weight are sprayed onto the spray forming pattern to form a deposit on the spray forming pattern. The deposit has a thickness of at least 0.5 inches and the temperature of the steel particles increases as the thickness of the steel deposit increases. The spraying conditions are controlled so that the steel particles coming into contact with the spray forming pattern results in a surface temperature of the spray forming pattern of less than about 80.degree. C. The deposit and the spray forming pattern are heated to a second temperature, which is higher than the first temperature, to melt the spray forming pattern from the deposit. The resulting deposit has the general shape of the master pattern.
    Type: Grant
    Filed: November 4, 1998
    Date of Patent: December 5, 2000
    Assignee: Visteon Global Technologies, Inc.
    Inventors: Jeffrey Alan Kinane, Grigoriy Grinberg, David Robert Collins, Paul Earl Pergande
  • Patent number: RE37854
    Abstract: A rigid bar (or segment) on which stones will be at least partially supported is positioned in a rubber mold for creating a wax pattern of the jewelry, injecting wax to form a wax model of the jewelry including the metal bar to fit into an incision in the stones. The model with the metal bar forms the invisible pre-set stone mount. Stones are then placed into set position in the wax pattern on opposite sides of the metal bar. Once the setting is complete, the jewelry is created using known “lost-wax” method of manufacturing jewelry.
    Type: Grant
    Filed: November 24, 1999
    Date of Patent: September 24, 2002
    Assignee: Nili Jewelry, Corp.
    Inventor: Manny Haimoff