Shell Type Mold Patents (Class 164/361)
  • Patent number: 11014144
    Abstract: A casting mould for casting complex-shaped castings from a molten metal. The casting mould has a mould cavity forming the casting and a delivery system that delivers molten metal into the mould cavity. The delivery system includes a sprue, a runner connected to the sprue and a feeder system connected to the runner. The mould cavity is connected to the feeder system or the runner via connections. When seen in the flow direction of the molten metal flowing from the sprue into the runner during the casting operation, the runner has a branch directed away from the sprue along the feeder system and has a directed-back branch adjoining the directed-away branch and guided along the feeder system in the opposite direction to the directed-away branch. The feeder system is connected to both the directed-away branch and the directed-back branch via two or more gates distributed along the respective branch.
    Type: Grant
    Filed: January 17, 2018
    Date of Patent: May 25, 2021
    Assignee: Nemak, S.A.B. de C.V.
    Inventors: Gerald Klaus, Dirk Schnubel, Carmen Schäfer, Christoph Tomczok, Tim Schneider, Steffen Spiess, Paulo Rossi
  • Patent number: 10766065
    Abstract: A component is formed from a component material introduced into a mold assembly. The mold assembly includes a mold that has a cavity defined therein by an interior wall. The cavity receives the component material in a molten state to form the component. A multiple component core assembly is positioned with respect to the mold and has a first core component attached to a second core component at a core split line. A core connection component is attached to each of the first and second core components at the core split line, such that the first core component is held adjacent the second core component at the core split line. The core connection component is formed from a connection component material that is at least partially absorbable by the component material.
    Type: Grant
    Filed: August 18, 2016
    Date of Patent: September 8, 2020
    Assignee: GENERAL ELECTRIC COMPANY
    Inventor: James Albert Tallman
  • Patent number: 10610922
    Abstract: A slurry composition includes, by volume, a ceramic composition in an amount of from about 60 to about 75 percent and a binder in an amount of from about 25 to about 40 percent, plus a platinum group metal catalyst and a dopant. The ceramic composition includes, by volume of the ceramic composition, fine fused silica particles having a particle size d50 of from about 4 ?m to about 7 ?m, in an amount of from about 7 to about 40 percent; coarse fused silica particles having a d50 of from about 25 ?m to about 33 ?m, in an amount of from about 29 to about 60 percent; inert filler particles having a d50 of from about 5 ?m to about 25 ?m, in an amount of from about 8 to about 40 percent; and fumed silica particles, in an amount of up to about 15 percent.
    Type: Grant
    Filed: September 8, 2017
    Date of Patent: April 7, 2020
    Assignee: General Electric Company
    Inventors: Sylvia Marie DeCarr, Kimberly Ann Polishchuk, John Patrick Pollinger, Stephanie Lynn Knoeller, Joan McKiever
  • Patent number: 10301947
    Abstract: A method of manufacturing a component for a gas turbine engine according to an exemplary aspect of the present disclosure includes forming the component with a first manufacturing technique to include a first cavity and a second cavity, and a microcircuit in fluid communication with the first cavity, the component including an outer wall and a ribbed portion or a bulged portion extending from the outer wall. The exemplary method includes forming a plunged hole with a second manufacturing technique different from the first manufacturing technique to intersect at least a portion of the microcircuit and extend into the ribbed portion or the bulged portion.
    Type: Grant
    Filed: June 5, 2018
    Date of Patent: May 28, 2019
    Assignee: United Technologies Corporation
    Inventors: Tracy A. Propheter-Hinckley, Steven Bruce Gautschi, San Quach
  • Patent number: 10260353
    Abstract: A component includes a structural member and an outer wall covering the structural member with a gap between the outer wall and the structural member. The outer wall includes an array of holes, each of the array of holes extending from an exterior surface of the outer wall to an interior surface of the outer wall. The outer wall includes an array of recesses on the interior surface of the outer wall, each hole in the array of holes terminating within one of the array of recesses of the outer wall.
    Type: Grant
    Filed: November 30, 2015
    Date of Patent: April 16, 2019
    Assignee: Rolls-Royce Corporation
    Inventors: Kurt F. O'Connor, Matthew T. Kush
  • Patent number: 10024181
    Abstract: A casting mold assembly includes an airfoil defining section and a casting core. The airfoil defining section includes an outer mold wall and a direct-shelled inner mold wall. The direct-shelled inner mold wall is disposed within a forward chordwise portion of the airfoil defining section. The direct-shelled inner mold wall includes an aft end having an external radius measuring more than about 0.075 in. (1.9 mm). The casting core is secured within an aft chordwise portion of the airfoil defining section, and includes an aft end with an external radius measuring less than about 0.075 in. (1.9 mm). A cast component and a method for making the casting mold assembly are also disclosed.
    Type: Grant
    Filed: October 5, 2016
    Date of Patent: July 17, 2018
    Assignee: United Technologies Corporation
    Inventors: Steven J. Bullied, Carl R. Verner, Steven D. Porter, James B. Park
  • Patent number: 9981438
    Abstract: A pre-form CMC cavity and method of forming pre-form CMC cavity for a ceramic matrix component includes providing a mandrel, applying a base ply to the mandrel, laying-up at least one CMC ply on the base ply, removing the mandrel, and densifying the base ply and the at least one CMC ply. The remaining densified base ply and at least one CMC ply form a ceramic matrix component having a desired geometry and a cavity formed therein. Also provided is a method of forming a CMC component.
    Type: Grant
    Filed: June 9, 2015
    Date of Patent: May 29, 2018
    Assignee: General Electric Company
    Inventors: Philip Harold Monaghan, John McConnell Delvaux, Glenn Curtis Taxacher
  • Patent number: 9845270
    Abstract: A castable refractory material for use in the manufacture of refractory products including fused silica, ceramic fiber, microsilica and a bonding material comprising colloidal silica.
    Type: Grant
    Filed: March 27, 2015
    Date of Patent: December 19, 2017
    Assignee: PYROTEK ENGINEERING MATERIALS LIMITED
    Inventor: Mark Vincent
  • Patent number: 9835163
    Abstract: Provided is a method of manufacturing an impeller assembly, the method including providing an impeller including: a rotary shaft; a base portion radially extending outward from the rotary shaft; and a plurality of blades extending radially outward from the rotary shaft and disposed on the base portion, each of the plurality of blades provided apart from one another in a circumferential direction around the rotary shaft; providing a mold in an area between the plurality of blades; and forming a shroud covering upper portions of the plurality of blades and an upper portion of the mold, wherein the forming the shroud comprises applying a melted metal on the upper portions of the plurality of blades and the upper portion of the mold.
    Type: Grant
    Filed: May 13, 2014
    Date of Patent: December 5, 2017
    Assignee: Hanwha Techwin Co., Ltd.
    Inventor: Jong Kee Ahn
  • Publication number: 20150144287
    Abstract: A shell mold is described. The shell mold includes a facecoat, a sealcoat, and a support disposed in between the facecoat and the sealcoat. The support includes a stucco in a concentration greater than about 40 volume percent of the support. The stucco includes a material that has a thermal conductivity greater than about 285 W/m-K.
    Type: Application
    Filed: November 27, 2013
    Publication date: May 28, 2015
    Applicant: General Electric Company
    Inventors: Qi Zhao, Stephen Francis Rutkowski, Francis Johnson, Wanming Zhang, Min Zou
  • Publication number: 20150122450
    Abstract: A cast ceramic core (110), including: an airfoil portion (116) shaped to define an inner surface (56) of an airfoil (52) of a vane segment (50); and a shell portion (122) having a backside-shaping surface (120) shaped to define a backside surface (68) of a shroud (62) of the vane segment. The backside-shaping surface has a higher elevation (132) and a lower elevation (134). The higher elevation is set apart from a nearest point (138) on the airfoil portion by the lower elevation. The airfoil portion and the shell portion are cast as a monolithic body during a single casting pour.
    Type: Application
    Filed: November 7, 2013
    Publication date: May 7, 2015
    Inventors: Ching-Pang Lee, Gerald L. Hillier, Jae Y. UM, Gm Salam Azad
  • Publication number: 20150027653
    Abstract: A shell mold for manufacturing aircraft turbomachine bladed elements using a lost wax molding technique, including: shell mold bladed elements including a blade portion located between a first end part delimiting an impression of a platform and a second end part delimiting an impression of another platform, with the blade portion including a trailing edge zone; a metal feeder having a central axis around which the bladed elements are distributed; and one or a plurality of screens that form heat accumulators arranged in a shell mold interior space, across from inwardly directed trailing edge zones.
    Type: Application
    Filed: January 22, 2013
    Publication date: January 29, 2015
    Applicant: SNECMA
    Inventors: Didier Guerche, Thibault Dalon
  • 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: 8931544
    Abstract: A bonded refractory mold is disclosed. The mold includes a mold wall. The mold wall includes a bonded 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. The mold also includes a gas vent extending through the mold wall. The mold also includes a gas permeable cover covering the gas vent.
    Type: Grant
    Filed: March 15, 2013
    Date of Patent: January 13, 2015
    Assignee: Metal Casting Technology, Inc.
    Inventor: Attila P. Farkas
  • Patent number: 8851151
    Abstract: A system for producing cast components from molten metal. One form of the present invention includes a system for the precision pouring of molten metal within a casting mold.
    Type: Grant
    Filed: March 25, 2005
    Date of Patent: October 7, 2014
    Assignee: Rolls-Royce Corporation
    Inventors: Donald J. Frasier, Matthew Kush, Max Eric Schlienger, Michael Baldwin
  • Patent number: 8844607
    Abstract: A system for producing cast components from molten metal. One form of the present invention includes a system for the precision pouring of molten metal within a casting mold. The precision pouring system is driven by a pressure differential.
    Type: Grant
    Filed: December 5, 2007
    Date of Patent: September 30, 2014
    Assignee: Rolls-Royce Corporation
    Inventors: Donald J. Frasier, Guy Allen Brady, Matthew T. Kush, Patrick A. Vessely
  • Publication number: 20140271129
    Abstract: A method is provided for making a mold for casting advanced turbine airfoils (e.g. gas turbine blade and vane castings) which can include complex internal and external air cooling features to improve efficiency of airfoil cooling during operation in the gas turbine hot gas stream. The method steps involve incorporating at least one fugitive insert in a ceramic material in a manner to form a core and at least a portion of an integral, cooperating mold wall wherein the core defines an internal cooling feature to be imparted to the cast airfoil and the at least portion of the mold wall has an inner surface that defines an external cooling feature to be imparted to the cast airfoil, selectively removing the fugitive insert, and incorporating the core and the at least portion of the integral, cooperating mold wall in a mold for receiving molten metal or alloy cast in the mold.
    Type: Application
    Filed: March 12, 2013
    Publication date: September 18, 2014
    Applicant: Howmet Corporation
    Inventors: Boyd A. Mueller, Michael A. Pepper, Daren K. Rogers, Gail R. Cole
  • Publication number: 20140241938
    Abstract: A ceramic casting vessel (92) including an insert (94) extending between a shell (91) and a core (93) of the vessel to define a cooling channel of an alloy component cast therein. The insert may include a portion (96) running generally parallel to a surface of the shell to define a cooling channel running generally parallel to a surface of the component. Ends of the insert may be disposed in respective grooves (95, 97) formed in the shell and/or core.
    Type: Application
    Filed: May 2, 2014
    Publication date: August 28, 2014
    Applicant: SIEMENS ENERGY, INC.
    Inventors: Gary B. Merrill, MIchael P. Appleby, Iain Alasdair Fraser, Jill Klinger, John R. Paulus
  • 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
  • Publication number: 20140190647
    Abstract: An investment casting method involves producing a casting shell by applying a hardenable refractory material to a sacrificial pattern. The casting shell having a plurality of phosphate bonds in the hardenable refractory material, which provide increased structural integrity during casting and improved frangibility during shell removal. The casting shell may also have a plurality of gaseous pockets suspended in the refractory material, which do not degrade the structural integrity during casting and provide improved frangibility during shell removal.
    Type: Application
    Filed: January 7, 2013
    Publication date: July 10, 2014
    Applicant: WiSys Technology Foundation, Inc.
    Inventors: Daniel Scott McGuire, Eric Ernst Hellstrom
  • Patent number: 8708033
    Abstract: The disclosure relates generally to mold compositions comprising calcium aluminate and calcium titanate. The disclosure also relates to methods of molding and the articles so molded using the mold compositions. More specifically, the disclosure relates to calcium aluminate/calcium titanate mold compositions and methods for casting titanium-containing articles, and the titanium-containing articles so molded.
    Type: Grant
    Filed: August 29, 2012
    Date of Patent: April 29, 2014
    Assignee: General Electric Company
    Inventors: Bernard Patrick Bewlay, Joan McKiever, Brian Michael Ellis, Nicholas Vincent McLasky
  • Publication number: 20130168035
    Abstract: A casting assembly for manufacturing a lock of a railcar coupler includes drag and cope portions of a first mold that defines exterior surfaces of the lock, wherein the first mold comprises a first molding material. The casting assembly also includes a second mold formed of a second molding material. The second mold defines a cavity with an interior surface that substantially complements an exterior surface of the first mold. A down sprue is formed in the second mold. A gating system is formed in the second mold that and is in fluid communication with the down sprue. An in-gate is formed in the second mold and is in fluid communication with the gating system and the first mold.
    Type: Application
    Filed: December 28, 2011
    Publication date: July 4, 2013
    Inventors: F. Andrew Nibouar, Jerry R. Smerecky, Kelly S. Day, Nick Salamasick
  • Publication number: 20130139990
    Abstract: Certain exemplary embodiments can provide a system, machine, device, manufacture, circuit, and/or composition of matter adapted for and/or resulting from, and/or a method for activities that can comprise and/or relate to, a first form comprising: a plurality of surface artifacts that substantially spatially replicate a surface geometry of a stacked foil mold; and a prong that is adapted to form a hole in a cast product.
    Type: Application
    Filed: December 5, 2012
    Publication date: June 6, 2013
    Inventors: Michael Appleby, John Paulus, Iain Fraser, Jill Klinger, Benjamin Heneveld
  • Patent number: 8413709
    Abstract: A composite core die includes a reusable core die and a disposable core die; where the disposable core die is in physical communication with the reusable core die; and further where surfaces of communication between the disposable core die and the reusable core die serve as barriers to prevent the leakage of a slurry that is disposed in the composite core die.
    Type: Grant
    Filed: December 6, 2006
    Date of Patent: April 9, 2013
    Assignee: General Electric Company
    Inventors: Ching-Pang Lee, Hsin-Pang Wang, Ram Kumar Upadhyay, Paul Richard Myers, Marc Thomas Edgar, Thomas Donald Martyn, Eric Alan Estill
  • Patent number: 8307881
    Abstract: Casting molds suitable for directional solidification processes using a liquid cooling bath include a graded facecoat structure on a mold body. The graded facecoat structure includes an innermost layer and a delamination layer, wherein the delamination layer fractures upon cooling of the molten metal so as to separate the mold body from the innermost layer, which remains in contact with or in close proximity to the metal being cast. Also disclosed are directional solidification processes.
    Type: Grant
    Filed: January 6, 2009
    Date of Patent: November 13, 2012
    Assignee: General Electric Company
    Inventors: Shyh-Chin Huang, Andrew John Elliott, Michael Francis Xavier Gigliotti, Jr., Roger John Petterson, Stephen Francis Rutkowski
  • Publication number: 20120039718
    Abstract: A casting apparatus for producing a turbine rotor blade of a gas turbine, and to a turbine rotor blade produced therewith is provided. The casting apparatus includes a hollow ceramic shell mold, of which the pouring gate and cores arranged therein are oriented with respect to each other such that a hot casting material flowing into a cavity of the ceramic shell mold does not come in direct contact with the cores. Thus, so-called hot spots on cores are avoided, which until now have had negative effects on the solidification of the casting material. Especially in the region of the blade root of the turbine rotor blade to be produced improved solidification of the casting material may thus be obtained, reducing any disturbance in the structure of the solidified casting material.
    Type: Application
    Filed: April 15, 2010
    Publication date: February 16, 2012
    Applicant: Siemens Aktiengesellschaft
    Inventors: Fathi Ahmad, Uwe Paul
  • Patent number: 8100165
    Abstract: An investment casting core combination includes a metallic casting core and a ceramic feedcore. A first region of the metallic casting core is embedded in the ceramic feedcore. A mating edge portion of the metallic casting core includes a number of projections. The first region is along at least some of the projections. A number of recesses span gaps between adjacent projections. The ceramic feedcore includes a number of compartments respectively receiving the metallic casting core projections. The ceramic feedcore further includes a number of portions between the compartments and respectively received in the metallic casting core recesses.
    Type: Grant
    Filed: November 17, 2008
    Date of Patent: January 24, 2012
    Assignee: United Technologies Corporation
    Inventors: Justin D. Piggush, Karl A. Mentz, Richard H. Page, Jesse R. Christophel, Ricardo Trindade
  • Patent number: 8096343
    Abstract: In precision casting of metallic components with very thin passage ducts, in particular turbine blades, by the lost-wax process, the ceramic core pins provided for forming the passage ducts are covered and stabilized via a low-melting reinforcing coat prior to injection of the wax material required for forming the wax pattern for the production of the ceramic casting mold, with the low-melting reinforcing coat being melted out together with the wax material after the casting mold has been formed on. The ceramic core pins are therefore not damaged during the production of the wax pattern, enabling very thin passage ducts to be formed in the precision casting process.
    Type: Grant
    Filed: March 7, 2008
    Date of Patent: January 17, 2012
    Assignee: Rolls-Royce Deutschland Ltd & Co KG
    Inventor: Richard Whitton
  • Patent number: 8087450
    Abstract: Investment casting shells are manufactured by incorporating fumed metal oxide dispersions, or doped fumed metal oxides as a binder into the casting shell. The investment casting shells containing the fumed metal oxides have improved characteristics, such as increased strength and a reduced surface roughness.
    Type: Grant
    Filed: January 29, 2008
    Date of Patent: January 3, 2012
    Assignee: Evonik Degussa Corporation
    Inventors: Shawn Nycz, Robert Johnson, Fred Klaessig
  • Publication number: 20110315338
    Abstract: Shell molds and processes for making the shell molds that exhibit high emissivity in the red and infrared regions. In this manner, thermal resistance within a gap formed between solidifying cast metal and the interior mold surface is decreased. In one embodiment, the facecoat region is formed from a slurry composition comprising an aluminum oxide, a green chromium oxide and a silicon dioxide. In another embodiment, the facecoat region is formed from a slurry composition including zirconium silicate and silica with stucco layer of alumina is included.
    Type: Application
    Filed: September 7, 2011
    Publication date: December 29, 2011
    Applicant: GENERAL ELECTRIC COMPANY
    Inventors: Michael Francis Xavier Gigliotti, Shyh-Chin Huang, Adegboyega Masud Makinde, Roger John Petterson, Stephen Francis Rutkowski, Venkat Subramaniam Venkataramani
  • Publication number: 20110232857
    Abstract: An investment casting method involves producing a casting shell by applying a hardenable slurry to a sacrificial pattern. To hasten the hardening of the slurry into the shell, a stucco coat including a desiccant material having a high surface area is subsequently applied to the slurry.
    Type: Application
    Filed: September 28, 2010
    Publication date: September 29, 2011
    Inventors: Daniel S. McGuire, Eric E. Hellstrom
  • Patent number: 7967055
    Abstract: A substrate is coated by applying an essentially pure aluminum first layer to a surface of the substrate. At least a first portion of the first layer is oxidized so as to provide a protective coating of desired properties. The substrate may be a refractory metal-based investment casting core.
    Type: Grant
    Filed: October 4, 2007
    Date of Patent: June 28, 2011
    Assignee: United Technologies Corporation
    Inventors: Joseph J. Parkos, Jr., Gary M. Lomasney, Joshua E. Persky
  • Patent number: 7942188
    Abstract: A cast metal article, such as a turbine engine component, is made by shaping a body of refractory metal particles to form a molded refractory metal article. The molded refractory metal article is sintered to form a refractory metal core. Both the refractory metal article and a setter block may be sintered at the same time. At least a portion of the refractory metal core is enclosed with wax. The wax is at least partially enclosed with a covering of mold material. The wax is removed from the mold material to form an article mold cavity. The article mold cavity is filled with molten metal which solidifies to form a cast metal article. The refractory metal core is removed from the cast metal article.
    Type: Grant
    Filed: March 12, 2008
    Date of Patent: May 17, 2011
    Assignee: Vent-Tek Designs, LLC
    Inventors: Richard Albert Skelley, Jr., Richard Lee Kreske
  • Patent number: 7918265
    Abstract: An investment casting mold article includes a wall for retaining casting material and a cavity defined by the wall. The cavity includes an airfoil portion, a root portion adjacent to the airfoil portion, and a labyrinth seal portion extending from the root portion.
    Type: Grant
    Filed: February 14, 2008
    Date of Patent: April 5, 2011
    Assignee: United Technologies Corporation
    Inventors: Carl R. Verner, Steven J. Bullied
  • Patent number: 7882885
    Abstract: Systems and methods for reducing the potential for riser backfilling during investment casting are provided. In this regard, a representative method for performing investment casting includes: providing a mold having an opening communicating with an interior, the interior having a part cavity and a riser; providing an insert; and using the insert to form a physical barrier to reduce a potential for molten metal to backfill into the riser while the molten metal is introduced into the interior of the mold via the opening.
    Type: Grant
    Filed: February 18, 2008
    Date of Patent: February 8, 2011
    Assignee: United Technologies Corporation
    Inventors: Steven J. Bullied, Carl R. Verner, Mario P. Bochiechio
  • Patent number: 7810547
    Abstract: A single crystal seed for use in casting a single crystal article, consisting essentially of, in weight %, about 5.0% to about 40.0% Mo, up to 0.1% C and balance essentially Ni wherein the seed is disposed in a casting mold for casting a single crystal article.
    Type: Grant
    Filed: July 20, 2009
    Date of Patent: October 12, 2010
    Assignee: Howmet Research Corporation
    Inventors: Steven T. Schaadt, Brad J. Murphy, Lisa K. Koivisto
  • Patent number: 7779892
    Abstract: An investment casting core combination includes a metallic casting core and a ceramic feedcore. A first region of the metallic casting core is embedded in the ceramic feedcore. The metallic casting core includes a plurality of body sections. The first region is along at least some of the body sections. The metallic casting core includes a plurality of springs spanning gaps between adjacent body sections and unitarily formed therewith.
    Type: Grant
    Filed: May 9, 2007
    Date of Patent: August 24, 2010
    Assignee: United Technologies Corporation
    Inventors: Blake J. Luczak, Matthew A. Devore
  • Patent number: 7753104
    Abstract: A method involves forming a core assembly. The forming includes molding a first ceramic core over a first refractory metal core to form a core subassembly. The subassembly is assembled to a second ceramic core.
    Type: Grant
    Filed: October 18, 2006
    Date of Patent: July 13, 2010
    Assignee: United Technologies Corporation
    Inventors: Blake J. Luczak, Eric A. Hudson, James T. Beals, Eric L. Couch
  • Publication number: 20100116452
    Abstract: A method involves forming a core assembly. The forming includes molding a first ceramic core over a first refractory metal core to form a core subassembly. The subassembly is assembled to a second ceramic core.
    Type: Application
    Filed: October 18, 2006
    Publication date: May 13, 2010
    Inventors: Blake J. Luczak, Eric A. Hudson, James T. Beals, Eric L. Couch
  • Publication number: 20100018666
    Abstract: Shell molds and processes for making the shell molds that exhibit high emissivity in the red and infrared regions. In this manner, thermal resistance within a gap formed between solidifying cast metal and the interior mold surface is decreased. In one embodiment, the facecoat region is formed from a slurry composition comprising an aluminum oxide, a green chromium oxide and a silicon dioxide. In another embodiment, the facecoat region is formed from a slurry composition including zirconium silicate and silica with stucco layer of alumina is included.
    Type: Application
    Filed: July 25, 2008
    Publication date: January 28, 2010
    Applicant: General Electric Company
    Inventors: Michael Francis Gigliotti, Shyh-Chin Huang, Adegboyega Masud Makinde, Roger John Petterson, Stephen Francis Rutkowski, Venkat Subramaniam Venkataramani
  • Publication number: 20100000698
    Abstract: A casting system includes a core and a shell positioned relative to the core. A barrier coating is applied on at least one of the core and the shell.
    Type: Application
    Filed: July 2, 2008
    Publication date: January 7, 2010
    Inventors: Kirk C. Newton, Alan D. Cetel, Mario P. Bochiechio, James T. Beals, John Joseph Marcin
  • Publication number: 20090301680
    Abstract: A blade outer air seal (BOAS) casting core has first and second end portions and a plurality of legs. Of these legs, first legs each have: a proximal end joining the first end portion; a main body portion; and a free distal portion. Second legs each have: a proximal end joining the second end portion; a main body portion; and a free distal portion.
    Type: Application
    Filed: August 10, 2006
    Publication date: December 10, 2009
    Inventors: Susan M. Tholen, Paul M. Lutjen, Richard H. Page, Richard W. Hoff, Roger J. Gates, Michael F. Blair
  • Patent number: 7575038
    Abstract: A single crystal seed for use in casting a single crystal article, consisting essentially of, in weight %, about 5.0% to about 40.0% Mo, up to 0.1% C and balance essentially Ni.
    Type: Grant
    Filed: June 11, 2001
    Date of Patent: August 18, 2009
    Assignee: Howmet Research Corporation
    Inventors: Steven T. Schaadt, Brad J. Murphy, Lisa K. Koivisto
  • Patent number: 7575042
    Abstract: A method for forming an article is described. The method includes the step of applying a precursor material to at least one surface of a mold structure for casting the article, and curing the applied precursor material. The precursor material includes facecoat-forming constituents which can be curably converted into a facecoat; and a protective coating-former for the article being cast. Molten material is then introduced into the mold structure, so as to come in contact with the facecoat formed from the cured precursor material. The molten material is cooled, to form the article. The cured precursor material, which is in contact with a surface of the cast article, is then reacted with the article, to form the protective coating on the surface of the article. Related mold structures are also described.
    Type: Grant
    Filed: March 30, 2006
    Date of Patent: August 18, 2009
    Assignee: General Electric Company
    Inventors: Bernard Patrick Bewlay, Melvin Robert Jackson
  • Publication number: 20090183852
    Abstract: A foundry shell core includes an outer shell made of a polymerised sand and resin mixture suitable for withstanding the heat and metallostatic pressure produced by molten metal during casting, and of an inner core body made of a material suitable for being thermally dissolved before using the shell core forming an inner cavity inside the core itself that facilitates the intake of smoke and gases produced during the casting. Alternatively, the inner core body is dissolved after the solidification of the casting. The shell cores are obtained by injection with the use of a conventional core box into which the core bodies, previously obtained by a die, have been inserted.
    Type: Application
    Filed: October 23, 2006
    Publication date: July 23, 2009
    Applicant: BASSI TECHNOLOGY S.R.L. UNIPERSONALE
    Inventor: Bruno Bassi
  • Patent number: 7562691
    Abstract: The present invention relates to a ceramic core used in the manufacture, by lost wax casting, of a turbomachine blade with cooling cavities and a squealer, comprising at least one main core, wherein the main core (10) comprises an element (10B) shaped so as to constitute the squealer and an element (10SB) shaped so as to constitute at least one cavity beneath the squealer, the two elements leaving between them a space (13) shaped so as to constitute, at least in part, the bottom wall of the squealer. In particular, the elements (10B and 10SB) are joined together by ceramic rods (TG).
    Type: Grant
    Filed: July 26, 2006
    Date of Patent: July 21, 2009
    Assignee: SNECMA
    Inventors: Didier Guerche, Jean-Claude Hanny, Serge Prigent
  • Publication number: 20090169415
    Abstract: The object of the present invention is to provide a mold which has low reactivity with molten alloys and which is inexpensive, a method for manufacturing the same and a molded article using the mold. A mold 40 in accordance with the present invention serves for manufacturing a molded article 60 of a titanium-aluminum alloy or a titanium alloy. At least an initial layer 44a of a cavity surface 43 of a mold body 41 constituting the mold 40 is formed of a calcined product of a slurry comprising a filler having cerium oxide as a main component and a binder having silica sol as a main component.
    Type: Application
    Filed: September 7, 2006
    Publication date: July 2, 2009
    Applicants: IHI CORPORATION, ISHIKAWAJIMA PRECISION CASTING CO., LTD.
    Inventors: Kazuyoshi Chikugo, Shigeyuki Sato
  • Patent number: 7533713
    Abstract: Casting mold for metal casting, in particular precision casting of fine parts of steel, in which at least the main part of the casting mold is made of porous ceramic with a high thermal coefficient of expansion which corresponds to the metal, and produced by generative rapid prototyping process, as well as generative rapid prototyping processes and coated powders particularly suitable therefore, as well as uses of the casting mold for tools and their components, in particular of steel.
    Type: Grant
    Filed: April 16, 2004
    Date of Patent: May 19, 2009
    Assignee: Daimler AG
    Inventors: Rolf Pfeifer, Jialin Shen
  • Patent number: 7513296
    Abstract: Investment-casting shells are disclosed that have at least one cluster of individual club-head casting molds for casting thin-walled, titanium alloy club-heads at high process yield and low material usage. The shells have respective combinations of cluster configuration and number, gating, and runners, as determined systematically. Some shell configurations include a cluster of at least ten casting molds for respective club-heads each (a) having a head-volume greater than 400 cm3, (b) defining at least one club-head wall having a thickness of less than 0.8 mm, and (c) defining at least one respective gate. The cluster is configured to produce a cast-ptoduct yield of greater than 80% at a material usage of less than 600 g, including process losses, per cast club-head. Also, at least one runner connects the gates together.
    Type: Grant
    Filed: December 28, 2006
    Date of Patent: April 7, 2009
    Assignee: Taylor Made Golf Company, Inc.
    Inventors: Joseph Yu, Bing-Ling Chao
  • Patent number: 7500511
    Abstract: A slurry composition for a mold and method of use thereof. The slurry composition includes about 45-80% by weight alumina, about 10-30% by weight silicon carbide, and about 10-50% by weight colloidal silica. In one aspect, the alumina component comprises a material selected from the group consisting of brown fused alumina, white fused alumina, tabular alumina, calcined alumina, and mixtures thereof. In another aspect, the composition includes fumed silica at 2-5% by weight. The composition may also include a setting agent at 0.05-2% by weight.
    Type: Grant
    Filed: September 24, 2003
    Date of Patent: March 10, 2009
    Assignee: Magneco/Metrel, Inc.
    Inventors: George Connors, Shirish Shah