Production of multi-passage hollow casting

Patent metadata

Field	Value
Publication number	US-10722939-B2
Application number	US-201816023896-A
Country	US
Kind code	B2
Filing date	Jun 29, 2018
Priority date	Jun 29, 2018
Publication date	Jul 28, 2020
Grant date	Jul 28, 2020

Abstract

A method of fabricating a casting is provided. The method includes creating a mixture of ceramic powder and a binder, pouring the mixture around sacrificial patterns, executing a first thermal treatment to set the mixture into a solid mold without damaging the sacrificial patterns, executing a second thermal treatment to remove the sacrificial patterns without removing any of the binder from the solid mold, executing at least one of a third thermal treatment and a chemical treatment to remove a quantity of the binder to transform the solid mold into a solid breakaway mold and pouring molten metallic material into the solid breakaway mold.

First claim

What is claimed is:

1. A method of fabricating a casting, the method comprising:
creating a mixture of ceramic powder and a binder;
pouring the mixture around sacrificial patterns;
executing a first thermal treatment to set the mixture into a solid mold without damaging the sacrificial patterns;
executing a second thermal treatment to remove the sacrificial patterns without removing any of the binder from the solid mold;
executing at least one of a third thermal treatment and a chemical treatment to remove a quantity of the binder to transform the solid mold into a solid breakaway mold; and
pouring molten metallic material into the solid breakaway mold.

2. The method according to claim 1 , wherein the ceramic powder comprises a refractory material and the binder comprises a self-setting binder.

3. The method according to claim 1 , further comprising assembling a casting pour-cup with gating to the sacrificial patterns.

4. The method according to claim 1 , wherein the pouring comprises pouring the mixture around an entirety of exposed portions of the sacrificial patterns.

5. The method according to claim 1 , wherein the pouring comprises at least one of agitation, vibration, ultrasonic pressure and suction or vacuum.

6. The method according to claim 1 , further comprising pouring the mixture around the sacrificial patterns within a rigid container.

7. The method according to claim 1 , wherein the at least one of the third thermal treatment and the chemical treatment remove about 10% or less of the binder from the solid mold.

8. The method according to claim 1 , wherein the at least one of the third thermal treatment and the chemical treatment remove about 30% or more of the binder from the solid mold.

9. The method according to claim 1 , wherein a temperature of the metallic material is less than a slumping temperature of the solid breakaway mold.

10. The method according to claim 1 , further comprising:
allowing the molten material to cool into a metallic component within the solid breakaway mold; and
breaking the solid breakaway mold away from the metallic component following cooling.

11. A method of fabricating a casting, the method comprising:
creating a mixture of ceramic powder and a binder;
assembling sacrificial patterns to a casting pour-cup with gating in a rigid container;
pouring the mixture into the rigid container in a single pour around an entirety of exposed portions of the sacrificial patterns;
executing a first thermal treatment to set the mixture into a solid mold without thermally damaging the sacrificial patterns;
executing a second thermal treatment to remove the sacrificial patterns without thermally or chemically removing any of the binder from the solid mold;
executing at least one of a third thermal treatment and a chemical treatment to remove a quantity of the binder to transform the solid mold into a solid breakaway mold; and
pouring molten metallic material into the solid breakaway mold.

12. The method according to claim 11 , wherein the ceramic powder comprises a refractory material and the binder comprises a self-setting binder.

13. The method according to claim 11 , wherein the pouring comprises at least one of agitation, vibration, ultrasonic pressure and suction or vacuum.

14. The method according to claim 11 , wherein the at least one of the third thermal treatment and the chemical treatment remove about 10% or less of the binder from the solid mold.

15. The method according to claim 11 , wherein the at least one of the third thermal treatment and the chemical treatment remove about 30% or more of the binder from the solid mold.

16. The method according to claim 11 , wherein a temperature of the metallic material is less than a slumping temperature of the solid breakaway mold.

17. The method according to claim 11 , further comprising:
allowing the molten material to cool into a metallic component within the solid breakaway mold; and
breaking the solid breakaway mold away from the metallic component following cooling.

18. A method of fabricating a casting, the method comprising:
creating a mixture of refractory powder and a self-setting binder;
assembling sacrificial patterns to a casting pour-cup with gating in a rigid container;
pouring the mixture into the rigid container in a single pour around an entirety of exposed portions of the sacrificial patterns;
executing at least one of a three-part thermal treatment and a two-part thermal treatment with a chemical treatment to set the mixture into a solid mold without thermally damaging the sacrificial patterns, to remove the sacrificial patterns without thermally or chemically removing any of the binder from the solid mold and to remove a quantity of the binder to transform the solid mold into a solid breakaway mold;
pouring molten metallic material, which is coolable into a metallic component, into the solid breakaway mold; and
breaking the solid mold away from the metallic component.

19. The method according to claim 18 , wherein the pouring comprises at least one of agitation, vibration, ultrasonic pressure and suction or vacuum.

20. The method according to claim 18 , wherein the at least one of the third thermal treatment and the chemical treatment remove about 10% or less or 30% or more of the binder from the solid mold.

Assignees

• United Technologies Corp
• Raytheon Tech Corp

Inventors

• Marcin John Joseph
• Bullied Steven J
• Ranganath Santosh

Classifications

• B22F2003/248

  Thermal after-treatment · CPC title

• B22C9/043

  Removing the consumable pattern · CPC title

• B22D23/003

  Moulding by spraying metal on a surface · CPC title

• B22C1/16

  characterised by the use of binding agents; Mixtures of binding agents · CPC title

• B22C9/24

  for hollow articles · CPC title