Dual investment shelled solid mold casting of reticulated metal foams

Patent metadata

Field	Value
Publication number	US-9737930-B2
Application number	US-201514960744-A
Country	US
Kind code	B2
Filing date	Dec 7, 2015
Priority date	Jan 20, 2015
Publication date	Aug 22, 2017
Grant date	Aug 22, 2017

Abstract

A method to manufacture reticulated metal foam via a dual investment, includes pre-investment of a precursor with a diluted pre-investment ceramic plaster then applying an outer mold to the encapsulated precursor as a shell-mold.

First claim

What is claimed:

1. A method to manufacture reticulated metal foam via a dual investment, comprising:
pre-investing a precursor with a pre-investment ceramic plaster to encapsulate the precursor;
applying an outer mold to the encapsulated precursor as a shell-mold; and
coating the prescursor in a molten wax to increase ligament thickness to provide an about 90% air to 10% precursor ratio.

2. The method as recited in claim 1 , wherein the precursor is a reticulated foam.

3. The method as recited in claim 1 , wherein the precursor is a polyurethane foam.

4. The method as recited in claim 1 , wherein the precursor is completely encapsulated with the pre-investment ceramic plaster.

5. The method as recited in claim 1 , further comprising, coating the precursor to increase ligament thickness.

6. The method as recited in claim 1 , further comprising applying the outer mold by applying alternating layers of slurry and stucco to form the shell-mold.

7. A method to manufacture reticulated metal foam via a dual investment, comprising:
pre-investing a precursor with a pre-investment ceramic plaster to encapsulate the precursor;
applying an outer mold to the encapsulated precursor as a shell-mold,
wherein the pre-investment ceramic plaster is diluted to about 55:100 water-to-powder ratio.

8. A method to manufacture reticulated metal foam via a dual investment, comprising:
coating a precursor in a molten wax to increase ligament thickness;
pre-investing the waxed precursor with a pre-investment ceramic plaster to encapsulate the precursor; and
applying an outer mold to the encapsulated precursor as a shell-mold,
wherein the outer mold is more rigid than the pre-investment ceramic plaster.

9. A method to manufacture reticulated metal foam via a dual investment, comprising:
coating a precursor in a molten wax to increase ligament thickness;
pre-investing the waxed precursor with a pre-investment ceramic plaster to encapsulate the precursor; and
applying an outer mold to the encapsulated precursor as a shell-mold,
wherein the pre-investment ceramic plaster is diluted to a predetermined water-to-powder ratio.

10. A method to manufacture reticulated metal foam via a dual investment, comprising:
coating a precursor in a molten wax to increase ligament thickness;
pre-investing the waxed precursor with a pre-investment ceramic plaster to encapsulate the precursor; and
applying an outer mold to the encapsulated precursor as a shell-mold,
wherein the pre-investment ceramic plaster is diluted to an about 55:100 water-to-powder ratio.

11. A dual investment, comprising:
a precursor;
a pre-investment ceramic plaster over the precursor;
a shell mold over the pre-investment ceramic plaster; and
a molten wax over the precursor to increase ligament thickness to provide an about 90% air to 10% precursor ratio.

12. The dual investment as recited in claim 11 , wherein the precursor is reticulated foam.

13. A dual investment, comprising:
a precursor;
a pre-investment ceramic plaster over the precursor; and
a shell mold over the pre-investment ceramic plaster,
wherein the pre-investment ceramic plaster is diluted more than about 39-42:100.

Assignees

• United Technologies Corp

Inventors

• Breneman Ryan C
• Bullied Steven J
• Scott David R

Classifications

• B22C9/043

  Removing the consumable pattern · CPC title

• B22C9/22 Primary

  Moulds for peculiarly-shaped castings · CPC title

• B22D29/006

  by abrasive, water or air blasting · CPC title

• B22C1/00

  Compositions of refractory mould or core materials; Grain structures thereof (refractory materials in general C04B35/00); Chemical or physical features in the formation or manufacture of moulds · CPC title

• B22C9/04

  Use of lost patterns · CPC title