US20080000611A1 - Method for Forming Casting Molds - Google Patents

Method for Forming Casting Molds Download PDF

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Publication number
US20080000611A1
US20080000611A1 US11/427,105 US42710506A US2008000611A1 US 20080000611 A1 US20080000611 A1 US 20080000611A1 US 42710506 A US42710506 A US 42710506A US 2008000611 A1 US2008000611 A1 US 2008000611A1
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Prior art keywords
mold
casting
mixture
combinations
foregoing
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US11/427,105
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English (en)
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Ronald Scott Bunker
Canan Uslu Hardwicke
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General Electric Co
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General Electric Co
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Priority to US11/427,105 priority Critical patent/US20080000611A1/en
Assigned to GENERAL ELECTRIC COMPANY reassignment GENERAL ELECTRIC COMPANY ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: BUNKER, RONALD SCOTT, HARDWICKE, CANAN USLU
Priority to JP2007163248A priority patent/JP2008006502A/ja
Priority to RU2007124269/02A priority patent/RU2456116C2/ru
Priority to CN200710127108.7A priority patent/CN101096048B/zh
Priority to DE102007030096A priority patent/DE102007030096A1/de
Publication of US20080000611A1 publication Critical patent/US20080000611A1/en
Abandoned legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/22—Moulds for peculiarly-shaped castings

Definitions

  • This disclosure generally relates to casting, and, more specifically, to manufacturing molds used in casting operations.
  • Casting processes are widely employed for the formation of articles.
  • casting processes can be described as any process wherein a flowable material is introduced into a mold, allowed to solidify therein, and then removed in solid form.
  • Exemplary casting processes include investment casting, slip casting, gel casting, sand casting, plaster casting, die-casting, injection molding, slurry injection, powder forming (compaction), reaction forming, colloidal forming, cold isostatic pressing, hot isostatic pressing, and so forth.
  • investment casting in particular is extensively utilized as the investment core allows for the formation of cast articles having greater detail than is achievable in other casting processes and allows for the efficient production of the casting mold.
  • the investment casting process begins with fabricating a sacrificial wax pattern that comprises a similar geometrical shape as the desired cast part.
  • Patterns are normally made of investment casting wax that is injected into a metal mold via a wax injection molding process. Once a wax pattern is produced, it is assembled to other wax components to form a gate and runner system through which the casting material will flow. The entire wax assembly is then dipped in a ceramic slurry, covered with a sand stucco, and allowed to dry. The dipping and stuccoing process is repeated until a desired shell thickness is obtained (e.g., about 6-10 mm (0.25-0.675 in)). Once the ceramic has dried, the entire assembly is placed in a steam autoclave to remove a majority of the wax.
  • the ceramic mold can be formed in sections, such as mold halves, or even more sections, which can be assembled together to form the finished mold. This is advantageous as the mold can be disassembled to remove cast parts therefrom, enabling the mold to be utilized multiple times.
  • investment casting can provide improved detail and allow for casting molds to be formed using the dipping process
  • investment casting processes as well as other ceramic mold forming processes remain deficient in replicating fine surface features.
  • investment cores having surface features and/or textures such as patterns, protrusions and/or figuring that comprises intricate details and/or relatively small details (e.g., patterns comprising lines having a height that is less than or equal to about 0.010 inches) are generally poorly replicated (e.g., non-uniformly replicated and/or distorted) after the mold is heat treated.
  • Disclosed herein are methods for forming casting molds and methods for casting articles.
  • a method for forming a mold comprises casting a mold having a cavity surface, forming surface features on the cavity surface, wherein the surface features comprise a mixture, and heat treating the mixture.
  • an article is disclosed.
  • a method for forming a mold comprises forming a die, casting a mold within the die using a ceramic composition and a casting process selected from the group consisting of investment casting, slip casting, gel casting, sand casting, plaster casting, die-casting, injection molding, slurry injection, powder forming (compaction), reaction forming, colloidal forming, cold isostatic pressing, hot isostatic pressing, and combinations comprising at least one of the foregoing, heating the mold, extruding a mixture onto a cavity surface of the mold to form surface features thereon, wherein the mixture is extruded through the nozzle of an apparatus, and heat treating the mixture.
  • a casting process selected from the group consisting of investment casting, slip casting, gel casting, sand casting, plaster casting, die-casting, injection molding, slurry injection, powder forming (compaction), reaction forming, colloidal forming, cold isostatic pressing, hot isostatic pressing, and combinations comprising at least one of the foregoing, heating the mold, extruding a
  • articles are formed from the methods forming molds disclosed.
  • FIG. 1 is an exemplary illustration of a first die half.
  • FIG. 2 is an exemplary illustration of a second die half.
  • FIG. 3 is an exemplary illustration of a first die half filled with a ceramic composition.
  • FIG. 4 is an exemplary illustration of the second die half filled with a ceramic composition.
  • FIG. 5 is an exemplary illustration of a second mold half being removed from the first die half.
  • FIG. 6 is an exemplary illustration of the first mold half being removed from the second die half.
  • FIG. 7 is an exemplary illustration of the first mold half and the second mold half assembled.
  • FIG. 8 is an exemplary illustration of a pen depositing a mixture onto the cavity surface of the second die forming protrusions thereon.
  • FIG. 9 is an exemplary illustration of a molten alloy being poured into the sprue of the assembled die to form a turbine blade.
  • FIG. 10 is an exemplary illustration of a cast turbine blade comprising an exemplary pattern of dimples.
  • Disclosed herein is a method for forming surface features on casting molds comprising, after a mold has been formed, depositing metal and/or ceramic materials onto the surface of the casting mold to form the desired surface features thereon. Thereafter, the material can be heat treated to harden and bond it to the casting mold. The mold can then be employed to cast an article, wherein the surface features formed in the casting mold form the negative geometry in the cast part.
  • the method of forming surface features on a ceramic casting mold begins with the construction of the mold.
  • the mold can be formed via ceramic forming methods such as investment casting, slip casting, gel casting, sand casting, plaster casting, die-casting, injection molding, slurry injection, powder forming (compaction), reaction forming, colloidal forming, isostatic pressing (e.g., hot isostatic pressing or cold isostatic pressing), and so forth, as well as combinations comprising at least one of these methods.
  • the mold is constructed such that the internal surfaces of the mold are accessible to allow surface features to be formed thereon in a later process.
  • the mold can be formed in sections (e.g., mold halves), which can be assembled together to form the finished mold and disassembled to remove cast parts.
  • the materials employed for the mold can comprise materials that are capable of withstanding the temperatures endured during casting of desired cast articles, such as metallic parts, in particular heat resistant superalloys.
  • Exemplary materials comprise alumina, silica, and so forth.
  • One exemplary method employed for forming a casting mold employs a casting process wherein metal dies are constructed to form the casting mold halves.
  • the dies are formed with internal geometries that replicate the desired outer surfaces of the part to be cast and comprise the basic form of the mold. For example, refer now to FIGS. 1 and 2 wherein and exemplary first die half 2 and second die half 4 are illustrated.
  • the geometry of the first die half 2 and the second die half 4 will be employed to form a ceramic mold that will be utilized to cast a turbine blade.
  • the dies can be formed from metals, such as tool steels (e.g., P-20 mold steel having 0.28-0.40 wt. % carbon, 0.60-1.00 wt. % manganese, 0.20-0.80 wt.
  • AISI American Iron and Steel Institute
  • any metals can be employed that will endure (i.e., not melt or deform) at the temperatures at which the material employed to form the casting mold will be processed; e.g., generally a temperature of about 700° C.
  • the dies can be formed using metal working processes, (such as electrical discharge machining, milling, and grinding), rapid manufacturing methods (such as selective laser sintering, and layer deposition technologies), and so forth, as well as combinations comprising at least one of the foregoing processes.
  • the dies are filled with a ceramic composition 6 , as illustrated in FIGS. 3 and 4 .
  • the ceramic composition 6 can be compressed within the dies, using, for example, mechanical pressure (e.g., a punch), isostatic pressure techniques, and so forth.
  • a set of dies e.g., first die half 2 and second die half 4
  • isostatic pressing process wherein the ceramic composition 6 is subjected to about 15,000 pounds per square inch (psi) of pressure in a pressurized air chamber.
  • the ceramic composition 6 can employ ceramic powders such as alumina, silica, zirconia, zirconium silicate (zircon), aluminum silicate (mullite), yttria, yttrium silicate, yttrium aluminate (garnet), yttrium aluminate (Perovskite), rare-earth oxides, rare earth silicates, rare earth aluminates, and so forth, as well as combinations comprising at least one of the foregoing.
  • the specific ceramic powder(s) chosen will be based on the desired properties of the molds, such as thermal conductivity, wear resistance, and so forth.
  • the average particle size of the powders employed are also dependent upon the particular properties desired, such as surface roughness.
  • the average particle size is generally less than or equal to about 100 micrometers ( ⁇ m), and, more specifically, less than or equal to about 70 ⁇ m, and, even more specifically, less than or equal to about 30 ⁇ m.
  • the particle size influences the size of the specific surface features that can be replicated and the resulting surface finish of the mold.
  • the powder employed can comprise an average particle size of about 0.001 ⁇ m to about 10 ⁇ m.
  • the ceramic composition 6 can also comprise a liquid media (such as alcohol(s), water, and/or (oil(s)), to form a slurry.
  • a slurry can be advantageous if it is capable of flowing into complex mold geometries (e.g., undercuts, channels, and so forth).
  • Additives can also be added to the ceramic composition 6 .
  • Exemplary additives are reinforcing fibers (e.g., silica fibers), processing aids (such as mold release material(s), e.g., paraffin wax), binders (e.g., polyoxymethylene, starch, celluloses, and so forth), as well as combinations comprising at least one of the foregoing.
  • an alcohol can be added to a silica powder to form a slurry that is capable of flowing into a die at a desired rate.
  • a silica fiber is also added to the ceramic composition 6 to increase the strength of the mold, and the thickness of the mold (e.g., the walls of the mold, not shown) is configured such that the casting material cools at a desired rate to provide a desired microstructure in the cast article.
  • Exemplary materials can also be found in U.S. Pat. No. 4,989,664 (Roth), which is incorporated herein by reference.
  • the die halves/mold halves e.g., the die halve comprise the mold halves in the form of the ceramic composition 6 therein
  • the die halves/mold halves can be heated in an oven for an amount of time that is sufficient to bind the ceramic composition 6 .
  • the temperature is below a sintering temperature at this point in the process.
  • the die halves/mold halves can be heated for an additional amount of time to drive off any moisture or volatile liquids.
  • the oven employed can be equipped with a desiccant apparatus capable of drying the air within the oven during the process.
  • the ceramic composition 6 can shrink to some degree (e.g., a volumetric). If the shrinkage is predictable, the dies can be oversized so that the molds produced will shrink to the desired specifications.
  • the predictability of the ceramic composition's shrinkage can be increased by controlling the composition (e.g., particle size, purity, and so forth), and the ceramic mold's properties (e.g., density). For example, consistency in the particle size of the ceramic, the purity of the ceramic, the loading of additives, and other variables, can improve shrinkage predictability.
  • a hot isostatic pressing process can be employed to compress the ceramic composition 6 as it is heated. Employing such a process can also increase the density of the ceramic powders, which can reduce shrinkage when the molds are sintered.
  • the first mold half 8 and second mold half 10 are cooled (actively and/or passively), and are then removed from the die halves, as illustrated in FIG. 5 .
  • the first mold half 8 and second mold half 10 are prone to damage when they are removed from the die halves as the binders provide weak bonding of the ceramic powder.
  • the molds can be inspected and/or optionally modified when in the non-sintered state. For example, referring now to FIG. 7 , the first mold half 8 and the second mold half 10 are assembled so that they can be evaluated for fit, especially in areas of the parting line 14 and the cavity 16 . If modifications to the molds are desired, they can be achieved by machining and/or utilizing other modification methods.
  • vent(s) and sprue(s) can be machined into the mold halves to facilitate the flow of the casting material into the cavity 16 using a drilling or milling operation.
  • any flash around the parting line 14 can be removed utilizing a grinding operation and then the mold halves can be fitted with locators and/or guides so that the molds will be mated properly during a casting process.
  • the molds can be sintered at a temperature sufficient to cause the ceramic powder(s) to adhere to one another.
  • Exemplary temperatures generally employed are about 1,000° C. to about 2,200° C.
  • the time of the sintering process can vary based on the ceramic composition 6 , the mass and geometry of the molds, as well as other variables; however, generally it is about 8 hours to about 30 hours.
  • the sintering process can comprise various stages (e.g., temperature hold stages, temperature ramps, gradual cooling stages, and so forth), which can provide a mold comprising the desired microstructure, reduce warpage, reduce shrinkage, and so forth.
  • exemplary operations comprise inspection, coating processes (e.g., coatings to reduce surface roughness, wear resistant coatings, and so forth), machining processes (e.g., addition of vents, addition of sprues, removal of flash, and so forth), labeling processes, fixturing processes (e.g., within a carrier mold base), modification processes (e.g., addition of guides, and the addition of elements to attach the molds to one another), and so forth.
  • coating processes e.g., coatings to reduce surface roughness, wear resistant coatings, and so forth
  • machining processes e.g., addition of vents, addition of sprues, removal of flash, and so forth
  • labeling processes e.g., fixturing processes (e.g., within a carrier mold base)
  • modification processes e.g., addition of guides, and the addition of elements to attach the molds to one another
  • the cavity 16 FIG. 7
  • the cavity 16 can be polished.
  • Polishing the cavity 16 can be achieved either by polishing the actual interior surface of the cavity 16 , such as using an ultrasonic polishing apparatus with diamond paste, and/or by coating the desired surface with a coating, polishing the coating, heat treating the coating, and re-polishing. These processes can be repeated as many times as desired to yield an acceptable finish.
  • a slurry comprising a ceramic powder having an average diameter of less than or equal to about 100 ⁇ m can be applied to the surfaces of the cavity 16 . Thereafter, the slurry can be worked into the surface of the cavity (e.g., polished) and the cavity surface can be sintered. Next, the surface can be further polished and/or additional coats can be applied and the process can be repeated.
  • the interior surface of the cavity 16 can be finished with either ground or polished finishes.
  • Surface finishes which are ground generally comprise average surface roughness (Ra) values that are less than or equal to about 50 microinches, ⁇ in (1.27 ⁇ m).
  • Exemplary ground finishes can be represented by the Society for the Plastic Industry's surface finish characterization system, such as an SPI #6 surface finish, which is representative of surfaces produced using 320-grit paper exhibiting an Ra of about 38 to about 42 ⁇ in (0.97 ⁇ m to 1.07 ⁇ m), or an SPI #4 surface finish, which is representative of surfaces produced using 600-grit paper exhibiting an Ra of about 2 to about 3 ⁇ in (0.051 ⁇ m to 0.075 ⁇ m).
  • Exemplary polished finishes (i.e., glossy or high gloss finishes) generally comprise Ra values that are less than or equal to about 5 pin (0.127 ⁇ m), such as an SPI #3 surface finish, which is representative of surfaces produced via polishing with a grade #15 diamond buff exhibiting an Ra of about 2 to about 3 ⁇ in (0.051 ⁇ m to 0.075 ⁇ m), or an SPI #1 surface finish, which is representative of surfaces produced via polishing with a grade #3 diamond buff exhibiting an Ra of about 1 ⁇ in (0.025 ⁇ m).
  • an SPI #3 surface finish which is representative of surfaces produced via polishing with a grade #15 diamond buff exhibiting an Ra of about 2 to about 3 ⁇ in (0.051 ⁇ m to 0.075 ⁇ m)
  • SPI #1 surface finish which is representative of surfaces produced via polishing with a grade #3 diamond buff exhibiting an Ra of about 1 ⁇ in (0.025 ⁇ m).
  • the molds can be modified with surface features using an applicable deposition process.
  • exemplary deposition processes include chemical vapor deposition, ion plasma deposition, electron beam physical vapor deposition, and electroplating.
  • the specific deposition process can dispose a ceramic material onto the surface of the mold with the desired fidelity.
  • One exemplary deposition process is the “Direct Write” (DW) process, which also referred to as a “pen-type” or “nozzle” deposition process.
  • DW Direct Write
  • Exemplary Direct Write techniques e.g., pen, nozzle, laser, thermal spray, and so forth
  • U.S. patent application Ser. No. 11/170,579 Hardwicke, et al
  • U.S. Published Application No. 2005-0013926 Rutkowski et al
  • a pen 20 deposits a mixture 26 onto the cavity surface 24 of the second mold half 10 forming protrusions 22 thereon.
  • the mixture 26 flows through the pen 20 under pressure and exits at a nozzle 28 .
  • the pressure employed is dependent upon the desired flow rate as well as other variables such as the inner diameter of the nozzle 28 , the viscosity of mixture 26 , and so forth.
  • the size of the nozzle 28 is generally about 0.010 mm to about 1.0 mm, and is selected to provide a desired extrudate diameter.
  • the pen 20 is displaced relative to the cavity surface 24 and capable of translating along the cavity surface 24 to form surface features thereon.
  • surface features e.g., layers
  • the motion of the pen 20 coupled with control of the mixtures flow through the pen allow for layers, drops, smears, and combinations thereof to be formed by the pen 20 .
  • multiple passes of the pen 20 over an area can build layers of the mixture 26 and/or multiple pens can be employed to increased the speed of the deposition process or to modify multiple mold surface simultaneously.
  • the pen 20 can form a large number of surface features, wherein the term surface features is to be interpreted as any form created by disposing mixture 26 onto a surface, such as patterns (e.g., crosshatching, or weave patterns), drops, smears, layers, lines, shapes (e.g., circles, wavy lines, fish-scales, tessellations, or polygons), and so forth.
  • patterns e.g., crosshatching, or weave patterns
  • drops e.g., smears, layers, lines, shapes (e.g., circles, wavy lines, fish-scales, tessellations, or polygons), and so forth.
  • Controller 30 is connected in operational communication with the pen 20 .
  • the controller 30 is capable of controlling the motion of the pen 20 , the flow rate at which the mixture 26 is extruded from the pen 20 , and other processes and/or operations of the apparatus during operation.
  • the cavity surface 24 and a desired surface feature (protrusions 22 ) can be generated and stored in a computer as a CAD/CAM file that can be accessed by the controller 30 and executed to form the desired surface features on the cavity surface 24 . Therefore, these methods can be embodied in the form of computer or controller implemented processes and apparatuses for practicing those processes.
  • These methods can also be embodied in the form of computer program code containing instructions embodied in tangible media, such as floppy diskettes, CD-ROMs, hard drives, or any other computer-readable storage medium, wherein, when the computer program code is loaded into and executed by a computer or controller, the computer becomes an apparatus for practicing the method.
  • the methods may also be embodied in the form of computer program code or signal, for example, whether stored in a storage medium, loaded into and/or executed by a computer or controller, or transmitted over some transmission medium, such as over electrical wiring or cabling, through fiber optics, or via electromagnetic radiation, wherein, when the computer program code is loaded into and executed by a computer, the computer becomes an apparatus for practicing the method.
  • the computer program code segments configure the microprocessor to create specific logic circuits.
  • the mixture 26 employed by the pen 20 can comprise a slurry having a loading of about 50 to about 98 wt. % solids and a liquid.
  • the solids can be a metal (e.g., copper, gold, platinum, nickel, cobalt, titanium, or iron), a ceramic (e.g., alumina, zirconia, zirconium silicate (zircon), aluminum silicate (mullite), yttria, yttrium silicate, yttrium aluminate (garnet), yttrium aluminate (Perovskite), rare-earth oxides, rare earth silicates, rare earth aluminates, silica, silicon carbide, and so forth), and combinations comprising at least one of the foregoing, e.g., cobalt-based superalloys, nickel-titanium alloy, and so forth.
  • the specific powder employed will be chosen based on compatibility with the cavity surface 24 (e.g., ability
  • the liquid employed in the slurry can be any liquid that can be blended with the solids and allows the solids to flow into the mold, such as water, oils, alcohols, ethers, and so forth.
  • the mixture 26 can comprise additives, such as surfactants, binders (e.g., ethyl silicate and colloidal silica), processing aids (e.g., paraffin wax), viscosity modifiers, pore formers, and so forth.
  • a mixture comprises about 82 wt. % alumina, about 8 wt. % starch, and about 10 wt. % isopropyl alcohol.
  • the mixture 26 can be formulated in batches. For example, a 100 pound batch can be produced by first adding a silica ceramic powder having an average particle size of about 10 microns or less into a tumble drum. A starch binder and an alcohol carrier is added to the drum. The mixture 26 is then mixed using a rotating canister, high-speed blender, ribbon blender, or shear mixer (e.g., roll mill).
  • a rotating canister high-speed blender, ribbon blender, or shear mixer (e.g., roll mill).
  • the second mold half 10 is heated. During the heating process, the protrusions 22 (e.g., bumps, lines, and so forth) harden and fuse to the cavity surface 24 . In addition, any liquids, as well as any volatile additives, are evaporated.
  • the time and temperature employed to sinter the composition will be dependent upon the composition of the mixture 26 , the size of the protrusions 22 , and the heat source employed, among other variables. Exemplary heat treatments include focused energy sources (e.g., that employ a plasma, a microwave, a laser beam, an electron beam, and/or another local heat source).
  • the heat treatment may comprise heating the second mold half 10 in a furnace, provided the sintering temperature of the mixture 26 is less than the temperature at which the second mold half 10 can incur damage.
  • a masking process can be employed prior to the deposition process to mask portions of the cavity surface 24 that will not comprise surface features.
  • the specific masking employed can be a material that can adhere to the cavity surface 24 and will be easy to remove therefrom.
  • an adhesively backed polymer sheet can be employed.
  • the mold can thereafter be post processed using various operations such as those described above.
  • surface features can be formed on the surface(s) of the mold half(ves) before and/or after the optional processing of the mold (e.g., the polishing, coating, and/or other processes described above).
  • the molds can be assembled and employed for casting.
  • Materials that can be cast therein can comprise any article material(s) that melt at a temperature below that which would cause damage to the mold.
  • the material will desirably flow at a rate so that the die cavity 16 can be filled prior to solidification, or the mold can be preheated to retard solidification.
  • a casting material 34 e.g., nickel-based super alloy
  • the protrusions 22 formed by the deposition process are within the cavity 16 , and will therefore form indentations on the cast turbine blade.
  • An exemplary cast turbine blade 40 is shown in FIG. 10 .
  • the turbine blade 40 comprises surface details 42 (e.g, dimples), that were formed during casting by the protrusions 22 on the second mold half 10 .
  • the mold is disassembled and the casting is removed therefrom.
  • any additional post processing or secondary operations e.g., machining, polishing, coating, assembly, and so forth
  • machining, polishing, coating, assembly, and so forth can be employed.
  • exemplary operations comprise inspection, coating processes (e.g., coatings to reduce surface roughness and wear resistant coatings), machining processes (e.g., addition of vents, addition of sprues, and removal of flash), labeling processes, fixturing processes (e.g., within a carrier mold base), modification processes (e.g., addition of guides and addition of elements to attach the molds to one another), and so forth.
  • coating processes e.g., coatings to reduce surface roughness and wear resistant coatings
  • machining processes e.g., addition of vents, addition of sprues, and removal of flash
  • labeling processes e.g., fixturing processes (e.g., within a carrier mold base)
  • modification processes e.g., addition of guides and addition of elements to attach the molds to one another
  • a thermal barrier coating can be applied to the cavity to cover the cavity surface 24 and the protrusions 22 disposed thereon to provide a surface having a uniform surface finish.
  • Surface features can be formed on any ceramic and/or metal dies and/or molds employed for casting as well as cast articles.
  • a ceramic tool for polymer injection molding can be produced, wherein an investment core of the desired part can be employed in an investment casting process to form the ceramic mold.
  • the mold can then be subjected to a deposition process to form detailed patterns on the surface of the mold that will serve as a decoration on the injection molded articles formed therein.
  • These surface features can have a size of less than or equal to about 2,000 ⁇ m, or, more specifically less than about 1,000 ⁇ m, or, even more specifically, about 5 ⁇ m to about 500 ⁇ m.
  • the processes disclosed herein are particularly useful for forming surface features on the surfaces of molds that will be employed to form turbine engine components. While the formation of a turbine blade has been discussed herein, due to the high operating temperature of turbines, many components used therein are formed via casting processes that can employ the methods disclosed herein. For example, parts employed in the high-pressure stage of a turbine engine, such as stationary airfoils (e.g., nozzles or vanes) and rotating airfoils (e.g., buckets or blades). Other components used in areas of the turbine engine outside the high-pressure stage include shroud clearance control areas, which include flanges, casings, and rings, as well as combustor liners, and combustor domes.
  • shroud clearance control areas which include flanges, casings, and rings, as well as combustor liners, and combustor domes.
  • the methods herein are also useful in missile and rocket components such as booster cones, fins, and so forth.
  • Other applications include automotive applications (e.g., fuel injectors, turbocharger turbines and impellors, fuel reformers, and so forth), industrial applications (e.g., cast machine components), computer applications (e.g., storage device drive or cooling components), and so forth, as well as applications that form plastic articles.
  • the methods for forming surface features on casting molds described herein addresses an unmet need in the art.
  • the process allows for the formation of surface featured on a cavity surface of a casting mold, wherein the surface features can comprise intricate shapes, patterns, and so forth.
  • This method of producing cast articles with surface features is particularly useful in prototyping cast articles. To be more specific, this allows manufacturers of cast articles to start with the manufacture of a standard die which is used to form as many sets of standard casting molds (e.g., molds without surface features).
  • the standard casting molds can then be modified with the material deposition method disclosed herein to form differing surface features thereon.
  • the molds can be employed to then cast articles having the surface details formed by the surface features in the mold. For example, a series of turbine blades can be cast having varying surface features from molds all created from one die.
  • ranges are inclusive and independently combinable (e.g., ranges of “up to about 25 wt. %, or, more specifically, about 5 wt. % to about 20 wt. %,” is inclusive of the endpoints and all intermediate values of the ranges of “about 5 wt. % to about 25 wt. %,” etc.).
  • the modifier “about” used in connection with a quantity is inclusive of the stated value and has the meaning dictated by the context (e.g., includes the degree of error associated with measurement of the particular quantity).

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Turbine Rotor Nozzle Sealing (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
  • Powder Metallurgy (AREA)
  • Compositions Of Oxide Ceramics (AREA)
US11/427,105 2006-06-28 2006-06-28 Method for Forming Casting Molds Abandoned US20080000611A1 (en)

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US11/427,105 US20080000611A1 (en) 2006-06-28 2006-06-28 Method for Forming Casting Molds
JP2007163248A JP2008006502A (ja) 2006-06-28 2007-06-21 鋳型の形成方法
RU2007124269/02A RU2456116C2 (ru) 2006-06-28 2007-06-27 Способ формовки литейных форм
CN200710127108.7A CN101096048B (zh) 2006-06-28 2007-06-28 用于形成铸造模具的方法
DE102007030096A DE102007030096A1 (de) 2006-06-28 2007-06-28 Verfahren zur Gestaltung von Gussformen

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US8062715B2 (en) * 1998-06-30 2011-11-22 Skszek Timothy W Fabrication of alloy variant structures using direct metal deposition
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US11331832B2 (en) 2014-05-16 2022-05-17 Ford Global Technologies, Llc Method for finishing matching surfaces in forming tool components
CN105108883A (zh) * 2015-08-31 2015-12-02 徐超 一种陶瓷产品的注浆成型装置及使用方法
US11148199B2 (en) * 2016-07-29 2021-10-19 Tesla, Inc. Deposition of metal dies for part fabrication
US11033955B2 (en) 2017-10-03 2021-06-15 Raytheon Technologies Corporation Printing-enhanced casting cores
US11426790B2 (en) 2017-10-03 2022-08-30 Raytheon Technologies Corporation Printing-enhanced casting cores
US10955815B2 (en) * 2018-11-09 2021-03-23 Raytheon Technologies Corporation Method of manufacture using autonomous adaptive machining

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JP2008006502A (ja) 2008-01-17
DE102007030096A1 (de) 2008-01-03
RU2456116C2 (ru) 2012-07-20

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