Additively manufactured interlocking casting core structure with ceramic shell

Patent metadata

Field	Value
Publication number	US-11192172-B2
Application number	US-201715636282-A
Country	US
Kind code	B2
Filing date	Jun 28, 2017
Priority date	Jun 28, 2017
Publication date	Dec 7, 2021
Grant date	Dec 7, 2021

Abstract

A method of forming a cast component and a method of forming a casting mold. The method is performed by connecting at least one wax gate component to a ceramic core-shell mold. The ceramic core-shell mold includes at least a first core portion, a first shell portion, and a second shell portion, wherein the first shell portion is adapted to interface with at least the second shell portion to form at least one first cavity between the core portion and the first and second shell portions. The core-shell mold may be inspected and assembled prior to connection of the wax gate component. At least a portion of the ceramic core-shell mold and the wax gate component is coated with a second ceramic material. The wax gate component is then removed to form a second cavity in fluid communication with the first cavity.

First claim

What is claimed is:

1. A ceramic casting mold, comprising:
a first ceramic core portion and a first ceramic shell portion, the first ceramic core portion and the first ceramic shell portion adapted to interface with at least a second ceramic shell portion to form a first ceramic casting mold comprising a first cavity defined by the first ceramic core portion and each of the first and second ceramic shell portions, the first cavity adapted to define a cast component upon casting and removal of the ceramic casting mold, wherein a third ceramic shell portion contacts at least a portion of a surface of the first ceramic shell portion and a surface of the second ceramic shell portion and includes a second cavity providing fluid communication to the first cavity; and
a plurality of filaments joining the first ceramic core portion and the first ceramic shell portion, wherein each of the plurality of filaments is monolithic with the first ceramic core portion and the first ceramic shell portion and spans between the first ceramic core portion and the first ceramic shell portion, the plurality of filaments adapted to define a plurality of holes providing fluid communication between the first cavity within the cast component defined by the first ceramic core portion and an outer surface of the cast component upon removal of the ceramic casting mold.

2. The ceramic casting mold of claim 1 , wherein the second cavity, in fluid communication with the first cavity, is formed by the third ceramic shell portion, wherein the second cavity is formed by connecting at least one wax component to at least one of the first and second ceramic shell portions prior to forming the third ceramic shell portion.

3. The ceramic casting mold of claim 2 , wherein the third ceramic shell portion is formed by dipping the first ceramic shell portion, second ceramic shell portion, and the at least one wax component into a ceramic slurry.

4. The ceramic casting mold of claim 1 , wherein the third ceramic shell portion is formed by dipping the first ceramic shell portion and second ceramic shell portion into a ceramic slurry.

5. The ceramic casting mold of claim 1 , wherein the first ceramic shell portion and second ceramic shell portion are heat treated.

6. The ceramic casting mold of claim 1 , wherein the ceramic casting mold further comprises a second ceramic core portion adapted to interface with at least the first ceramic core portion.

7. The ceramic casting mold of claim 1 , wherein the first ceramic shell portion, the first ceramic core portion, the second ceramic shell portion, a second ceramic core portion, and the third ceramic shell portion are heat treated.

8. The ceramic casting mold of claim 1 , wherein the third ceramic shell portion covers at least an interface between the first ceramic shell portion and the second ceramic shell portion.

9. The ceramic casting mold of claim 1 , wherein the first ceramic shell portion, the first ceramic core portion, and the second ceramic shell portion are formed of a first ceramic material, and the third ceramic shell portion is formed of a second ceramic material different from the first ceramic material, wherein the second ceramic material has a different solubility, heat transfer coefficient, or porosity than the first ceramic material.

Assignees

• Gen Electric

Inventors

• Yang Xi
• Cole Michael
• Brown Michael
• Garay Gregory Terrence
• Pang Tingfan
• Przeslawski Brian David
• Konitzer Douglas Gerard

Classifications

• B22C9/22

  Moulds for peculiarly-shaped castings · CPC title

• B22C9/043

  Removing the consumable pattern · CPC title

• B22C9/24

  for hollow articles · CPC title

• B33Y10/00

  Processes of additive manufacturing · CPC title

• B28B7/346

  Manufacture of moulds · CPC title