Additively manufactured casting core-shell hybrid mold and ceramic shell

Patent metadata

Field	Value
Publication number	US-11235378-B2
Application number	US-201916531842-A
Country	US
Kind code	B2
Filing date	Aug 5, 2019
Priority date	Jun 28, 2017
Publication date	Feb 1, 2022
Grant date	Feb 1, 2022

Abstract

Integrated core-shell investment casting molds include a filament structure corresponding to a cooling hole pattern in the surface of the turbine blade, stator vane, or shroud.

First claim

What is claimed is:

1. A ceramic casting mold comprising:
a ceramic core portion, a first ceramic shell portion comprising a first ceramic material, a ceramic cover, and a second ceramic shell portion comprising a second ceramic material at least partially covering the first ceramic shell portion and the ceramic cover,
wherein the ceramic casting mold further comprises at least one cavity between the ceramic core portion and the first ceramic shell portion, the at least one cavity adapted to define a shape of a cast component upon casting and removal of the ceramic casting mold,
wherein the ceramic casting mold further comprises a plurality of filaments joining the ceramic core portion and the first ceramic shell portion, the plurality of filaments, the ceramic core portion and the first ceramic shell portion formed using an additive manufacturing process, where each of the plurality of filaments is monolithically formed with the ceramic core portion and the first ceramic shell portion and spans between the ceramic core and first ceramic shell portion, the plurality of filaments adapted to define a plurality of holes providing fluid communication between a cavity within the cast component defined by the 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 ceramic cover is adapted to define the shape of the cast component upon casting and removal of the ceramic casting mold.

3. The ceramic casting mold of claim 1 , wherein the ceramic cover defines a portion of the first cavity.

4. The ceramic casting mold of claim 1 , further comprising a passageway in fluid communication with the at least one cavity, the passageway comprising a gate portion attached to the ceramic casting mold.

5. The ceramic casting mold of claim 4 , wherein the second ceramic shell portion at least partially covers the gate portion.

6. The ceramic casting mold of claim 1 , wherein the second ceramic shell portion is formed by a dipping process followed by sintering.

7. The ceramic casting mold of claim 1 , wherein the second ceramic shell portion is formed by a spraying process followed by sintering.

8. The ceramic casting mold of claim 1 , wherein the second ceramic shell portion is configured to provide structural properties to covered portions of the first ceramic shell portion and the ceramic cover.

9. The ceramic casting mold of claim 1 , wherein the second ceramic shell portion is configured to increase durability of covered portions of the first ceramic shell portion and the ceramic cover.

10. The ceramic casting mold of claim 1 , wherein the second ceramic shell portion is configured to provide thermal properties to covered portions of the first ceramic shell portion and the ceramic cover.

11. The ceramic casting mold of claim 1 , wherein the second ceramic shell portion is configured to provide variable thermal conductivity to the ceramic casting mold.

12. The ceramic casting mold of claim 1 , wherein the plurality of filaments are cylindrical or oval in shape.

13. The ceramic casting mold of claim 1 , wherein the plurality of filaments are curved or non-linear.

14. The ceramic casting mold of claim 1 , wherein the plurality of filaments have a cross sectional area ranging from 0.01 to 2 mm 2 .

15. The ceramic casting mold of claim 1 , wherein the plurality of filaments have a cross sectional area ranging from 0.01 to 0.15 mm 2 .

16. The ceramic casting mold of claim 1 , wherein the plurality of filaments have a cross sectional area ranging from 0.05 to 0.1 mm 2 .

17. The ceramic casting mold of claim 1 , wherein the plurality of filaments have a cross sectional area ranging from 0.05 to 0.2 mm 2 .

18. The ceramic casting mold of claim 1 , wherein the plurality of filaments have a cross sectional area ranging from 0.1 to 0.18 mm 2 .

19. The ceramic casting mold of claim 1 , wherein the plurality of filaments have a cross sectional area ranging from 0.01 to 2 mm 2 .

20. The ceramic casting mold of claim 1 , wherein the plurality of filaments have a length ranging from 0.5 to 5 mm or an angle relative to the first ceramic shell portion of 5 to 35 degrees.

Assignees

• Gen Electric

Inventors

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

Classifications

• B22C9/10 Primary

  Cores; Manufacture or installation of cores {(breaker cores B22C9/084)} · CPC title

• B22D29/002

  by leaching, washing or dissolving · CPC title

• B28B1/001

  Rapid manufacturing of 3D objects by additive depositing, agglomerating or laminating of material (selective deposition modelling of metallic powder B22F10/00; rapid manufacturing of 3D objects in general and in particular of plastics B29C64/00) · CPC title

• B22C9/22

  Moulds for peculiarly-shaped castings · CPC title

• B28B11/045

  by dipping · CPC title