Spherical fused silica compositions for injection molded ceramic cores and methods of making parts using such compositions

Patent metadata

Field	Value
Publication number	US-12017268-B2
Application number	US-202217660038-A
Country	US
Kind code	B2
Filing date	Apr 21, 2022
Priority date	Apr 21, 2022
Publication date	Jun 25, 2024
Grant date	Jun 25, 2024

Abstract

A single crystal ceramic core composition has an inorganic portion and an organic portion. The inorganic portion makes up about 85% by weight of the total weight of the ceramic core composition, and the organic portion makes up about 15% by weight of the total weight of the ceramic core composition. The inorganic portion includes about 94 to 98% by weight spherical fused silica, and about 2 to 6% by weight zircon flour. The organic portion includes about 84 to 88% by weight binder, about 1 to 2% by weight dye, about 6 to 12% by weight surfactant, and about 1 to 5% by weight polymeric fiber.

First claim

What is claimed is:

1. A single crystal ceramic core composition, comprising:
an inorganic portion comprising about 85% by weight of the total weight of the ceramic core composition, the inorganic portion comprising:
about 94 to 98% by weight spherical fused silica; and
about 2 to 6% by weight zircon; and

an organic portion comprising about 15% by weight of the total weight of the ceramic core composition, the organic portion comprising:
about 84 to 88% by weight binder;
about 1 to 2% by weight dye;
about 6 to 12% by weight surfactant; and
about 1 to 5% by weight polymeric fiber.

2. The ceramic core composition of claim 1 , wherein:
the inorganic portion of the ceramic core composition comprises:
95 to 97% by weight spherical fused silica; and
3 to 5% by weight zircon; and

the organic portion of the ceramic core composition comprises:
86 to 87% by weight binder;
1.2 to 1.6% by weight dye;
8 to 10% by weight surfactant; and
2 to 4% by weight polymeric fiber.

3. The ceramic core composition of claim 2 , wherein the spherical fused silica comprises a plurality of particles, the plurality of particles having the following particle size distribution:

size of particle

% of particles
(in microns)

0-3
<1.16

  0-1.5
1.16-1.64

  0-1.8
1.64-2.31

1.4-2.4
2.31-3.27

1.6-2.6
3.27-4.62

2.0-3.0
4.62-6.54

2.9-3.9
6.54-9.25

4.4-5.4
 9.25-13.08

6.6-7.6
13.08-18.50

 9.2-10.2
18.50-26.16

12.7-13.7
26.16-37.0 

16.9-17.9
 37.0-52.33

16.7-17.7
52.33-74.0 

 9.6-10.6
 74.0-104.7

3.9-4.9
104.7-148.0

1.4-2.4
148.0-209.3

1.4-2.4
209.3-296.0

0-2
>296.0.

4. The ceramic core composition of claim 1 , wherein the spherical fused silica comprises a plurality of particles, the plurality of particles having the following particle size distribution:

size of particle

% of particles
(in microns)

0-3
<1.16

  0-1.5
1.16-1.64

  0-1.8
1.64-2.31

1.4-2.4
2.31-3.27

1.6-2.6
3.27-4.62

2.0-3.0
4.62-6.54

2.9-3.9
6.54-9.25

4.4-5.4
 9.25-13.08

6.6-7.6
13.08-18.50

 9.2-10.2
18.50-26.16

12.7-13.7
26.16-37.0 

16.9-17.9
 37.0-52.33

16.7-17.7
52.33-74.0 

  9.6-10.6
 74.0-104.7

3.9-4.9
104.7-148.0

1.4-2.4
148.0-209.3

1.4-2.4
209.3-296.0

0-2
>296.0.

Assignees

• Chromalloy Gas Turbine Llc

Inventors

• Dodds Gerald C
• Haber Mark S
• Baierl Zachary E

Classifications

• C04B2235/9676

  against molten metals such as steel or aluminium · CPC title

• C04B2235/6022

  Injection moulding · CPC title

• C04B2235/5436

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

• C04B2235/528

  Spheres · CPC title

• C04B2235/5212

  Organic · CPC title