Moulds for investment casting, methods of making such moulds and use thereof

Patent metadata

Field	Value
Publication number	US-11072022-B2
Application number	US-201615743370-A
Country	US
Kind code	B2
Filing date	Jul 8, 2016
Priority date	Jul 10, 2015
Publication date	Jul 27, 2021
Grant date	Jul 27, 2021

Abstract

The present invention relates to investment casting moulds comprising a furnace dust, wherein said furnace dust comprises ZrO2 and/or Al2O3. The present invention also relates to investment casting moulds comprising a metal oxide dust comprising ZrO2 and one or more materials selected from alumina, silica and aluminosilicate, and wherein said metal oxide dust has a d50 of 10 μm or less. The invention also relates to compositions for the production of investment casting moulds, the use of dusts in the formation of investment casting moulds, and the use of investment casting moulds of the invention.

First claim

The invention claimed is:

1. An investment casting mould comprising a fine particulate composition, wherein said fine particulate composition comprises ZrO 2 and/or Al 2 O 3 ; and wherein said fine particulate composition comprises no more than 3 wt. % of impurities other than alumina, silica, aluminosilicate and ZrO 2 .

2. An investment casting mould according to claim 1 , wherein said fine particulate composition is present in an amount of 0.5 to 25 wt. %, based on the total solids content of the mould.

3. An investment casting mould according to claim 1 , wherein said mould further comprises a kaolin and/or metakaolin.

4. An investment casting mould according to claim 1 , further comprising ceramic fibers and/or organic fibers.

5. An investment casting mould according to claim 1 , wherein said fine particulate composition has a d 50 of 5 μm or less, a d 90 of 50 μm or less, and a d 99 of 100 μm or less.

6. An investment casting mould comprising a dust, wherein said dust comprises ZrO 2 and one or more materials selected from alumina, silica and aluminosilicate, and wherein said dust has a d 50 of 10 μm or less, and wherein said dust comprises no more than 3 wt. % of impurities other than alumina, silica, aluminosilicate and ZrO 2 .

7. An investment casting mould according to claim 6 , wherein said dust is present in an amount of 0.5 to 25 wt.-%, based on the total solids content of the mould.

8. An investment casting mould according to claim 6 , wherein said dust comprises greater than 75 wt. % silica and up to 25 wt. % ZrO 2 .

9. An investment casting mould according to claim 6 , wherein said dust comprises greater than 40 wt.-% alumina, 25 to 50 wt. % silica and 5 to 25 wt. % ZrO 2 .

10. An investment casting mould according to claim 6 , wherein said dust has a d 50 of 5 μm or less, a d 90 of 50 μm or less, or a d 99 of 100 μm or less.

11. An investment casting mould according to claim 6 , wherein said dust has a multimodal particle size distribution.

12. An investment casting mould according to claim 6 , wherein said mould further comprises a kaolin and/or metakaolin.

13. An investment casting mould according to claim 6 , wherein said dust is a furnace dust obtained as a by-product from the production of fused zirconia or fused alumina-zirconia.

14. An investment casting mould according to claim 6 , further comprising ceramic fibers and/or organic fibers.

15. An investment casting mould according to claim 6 , wherein said dust has a d 50 of 5 μm or less, a d 90 of 50 μm or less, and a d 99 of 100 μm or less.

16. A composition for the production of an investment casting mould, said composition comprising a dust wherein said dust comprises ZrO 2 and one or more materials selected from alumina, silica and aluminosilicate, and wherein said metal oxide dust has a d 50 of 10 μm or less, and wherein said dust comprises no more than 3 wt. % of impurities other than alumina, silica, aluminosilicate and ZrO 2 .

17. A composition according to claim 16 , wherein said composition is a water-based slurry or an alcohol-based slurry.

18. A composition according to claim 16 , wherein said composition is a slurry having a filler load of 60 wt. % or more and a viscosity according to Zahn 4 of 35 s or less.

19. A composition according to claim 16 , further comprising ceramic fibers and/or organic fibers.

Assignees

• Imertech Sas

Inventors

• Krumrei Thomas
• Graddick Scot
• Frulli Danilo
• Wolff Joachim

Classifications

• C04B35/62204

  using waste materials or refuse (clay-wares containing waste materials C04B33/132) · CPC title

• C04B35/18

  rich in aluminium oxide · CPC title

• C04B2235/5445

  submicron sized, i.e. from 0,1 to 1 micron · CPC title

• C04B2235/5463

  Particle size distributions · CPC title

• C04B2235/5436

  micrometer sized, i.e. from 1 to 100 micron · CPC title