Casting insert and production method

Patent metadata

Field	Value
Publication number	US-2023321718-A1
Application number	US-202118042322-A
Country	US
Kind code	A1
Filing date	Jul 20, 2021
Priority date	Aug 20, 2020
Publication date	Oct 12, 2023
Grant date	—

Abstract

A casting insert includes a casting insert wall formed substantially of a liquid-phase-sintered refractory metal alloy, a cavity formed by the casting insert wall, and at least one cooling duct, which is different from the cavity and which is formed at least partly within the cavity and/or which is formed at least partly within the casting insert wall. The casting insert wall has a wall thickness which can be defined as a normal distance between a point of the casting insert wall which faces the cavity and a point on an outer surface of the casting insert wall. The wall thickness is, at least in sections, less than 25% of a diameter of the casting insert.

First claim

1 - 15 . (canceled)

16 . A casting insert, comprising:
a casting insert wall having an outer surface, said casting insert wall formed at least partially from a liquid-phase-sintered refractory metal alloy; said casting insert wall forming a cavity; at least one cooling duct being different from said cavity, said at least one cooling duct being at least one of configured at least in sections within said cavity or configured at least in sections within said casting insert wall; said casting insert wall having a wall thickness, said wall thickness being definable as a normal distance between a point of said casting insert wall facing said cavity and a point on said outer surface of said casting insert wall, and said wall thickness, at least in sections, being less than 25% of a diameter of the casting insert.

17 . The casting insert according to claim 16 , which further comprises a support structure interconnecting said casting insert wall and said at least one cooling duct.

18 . The casting insert according to claim 17 , wherein said support structure is configured as at least one of discrete crosspieces or discrete ribs.

19 . The casting insert according to claim 17 , wherein said support structure and said casting insert wall are formed of the same material.

20 . The casting insert according to claim 16 , wherein said at least one cooling duct and said casting insert wall are formed of the same material.

21 . The casting insert according to claim 16 , wherein said at least one cooling duct has a spiral-shaped profile at least in sections.

22 . The casting insert according to claim 16 , wherein said at least one cooling duct has cross-sectional variations at least in sections.

23 . The casting insert according to claim 16 , which further comprises a filling formed of a fill material differing from a material of said casting insert wall, said cavity between said casting insert wall and said at least one cooling duct at least partially containing said filling.

24 . The casting insert according to claim 23 , wherein said fill material is selected from the group including copper and copper alloys.

25 . The casting insert according to claim 16 , wherein said casting insert wall has at least one section having characteristics of having been produced by an additive manufacturing process.

26 . The casting insert according to claim 16 , wherein said casting insert wall and said at least one cooling duct have characteristics of having been produced in one piece by an additive manufacturing process.

27 . A method for producing a casting insert, the method comprising steps of:
producing the casting insert according to claim 16 by:
providing a powder of a liquid-phase-sinterable refractory metal alloy and at least one organic binder constituent;
producing a green body by additively constructing at least one section of the casting insert wall from the powder treated with the at least one organic binder constituent;
debindering the produced green body to obtain a brown body;
sintering the brown body in an at least temporary presence of liquid phase to yield a metallic blank of the casting insert; and
optionally performing finishing of the blank to obtain the casting insert.

28 . The method according to claim 27 , which further comprises producing at least one section of the at least one cooling duct by additive construction, simultaneously with the construction of the at least one section of the casting insert wall.

29 . The method according to claim 27 , which further comprises simultaneously producing a support structure interconnecting the casting insert wall and the at least one cooling duct at least in sections, by additive construction.

30 . The method according to claim 27 , which further comprises at least partially filling the cavity with a fill material differing from a material of the casting insert wall.

Assignees

• Plansee Se

Inventors

• Handtrack Dirk
• Kestler Heinrich

Classifications

• B22D17/2218 Primary

  Cooling or heating equipment for dies (for permanent moulds B22C9/065; for plastics B29C45/73) · CPC title

• B22F10/10

  Formation of a green body · CPC title

• B22F10/64

  by thermal means (control of energy beam parameters for post heating B22F10/364) · CPC title

• B22F10/66

  by mechanical means · CPC title

• B33Y10/00

  Processes of additive manufacturing · CPC title