Patent application number | Description | Published |
20090065168 | LOST WAX INVESTMENT CASTING GATING FIXTURES - A method of forming a gating fixture for a lost wax casting process includes determining an optimal orientation of a gate in relation to a part, and forming a fixture that can repeatably be used to consistently locate the gate relative to the part. In one example, stereolithography is used to form the fixture. | 03-12-2009 |
20090146341 | Systems and Methods Involving Pattern Molds - System and methods involving pattern molds are provided. In this regard, a representative system includes a mold assembly unit having a movable fixture holder operative to engage a portion of a pattern mold and position the pattern mold for assembly. | 06-11-2009 |
20090205800 | Systems and Methods for Reducing the Potential for Riser Backfilling During Investment Casting - Systems and methods for reducing the potential for riser backfilling during investment casting are provided. In this regard, a representative method for performing investment casting includes: providing a mold having an opening communicating with an interior, the interior having a part cavity and a riser; providing an insert; and using the insert to form a physical barrier to reduce a potential for molten metal to backfill into the riser while the molten metal is introduced into the interior of the mold via the opening. | 08-20-2009 |
20090208769 | Method and apparatus for as-cast seal on turbine blades - An investment casting mold article includes a wall for retaining casting material and a cavity defined by the wall. The cavity includes an airfoil portion, a root portion adjacent to the airfoil portion, and a labyrinth seal portion extending from the root portion. | 08-20-2009 |
20100084106 | PROCESS FOR CASTING COLUMNAR GRAIN AIRFOIL WITH PREFERENTIAL PRIMARY ORIENTATION - A molding process utilizes a seed with a columnar grain structure for defining a desired grain structure in a completed casting. The seed is received within a seed cavity of a mold. The molten material adopts the orientation of the columns defined within the seed during solidification to form a completed molded article having a desired columnar grain structure. | 04-08-2010 |
20100219325 | METALLIC COATED CORES TO FACILITATE THIN WALL CASTING - A core for investment casting processes includes a core comprising one or more ceramic materials; and an exterior layer of metal material not susceptible to oxidation under investment casting operating conditions. A method for casting a turbine engine component having an internal passageway includes the steps of forming one or more mold sections each having internal surfaces and at least one of the aforementioned cores for forming one or more turbine engine components having at least one internal passageway; assembling the one or more mold sections; introducing a molten alloy into the one or more assembled mold sections; and consuming the metal of the at least one core during the process. | 09-02-2010 |
20100238967 | METHOD OF PRODUCING A FINE GRAIN CASTING - An induction heated furnace assembly for producing a directionally solidified casting includes a susceptor that tailors strength of the magnetic field within the chamber to provide a desired grain structure in a completed cast part. The susceptor proportionally blocks portions of the magnetic field to provide different levels of magnetic stirring within the molten material at different locations within the furnace assembly stirring induced by the magnetic field is controlled and varied throughout the furnace assembly to create the desired grain structures in the completed cast article. | 09-23-2010 |
20100276103 | Metallic Coated Cores to Facilitate Thin Wall Casting - A core for investment casting processes includes a core having one or more ceramic materials; and an exterior layer of metal material not susceptible to oxidation under investment casting operating conditions. A method for casting a turbine engine component having an internal passageway includes the steps of forming one or more mold sections each having internal surfaces and at least one of the aforementioned cores for forming one or more turbine engine components having at least one internal passageway; assembling the one or more mold sections; introducing a molten alloy into the one or more assembled mold sections; and consuming the metal of the at least one core during the process. | 11-04-2010 |
20110186258 | FORMING A CAST COMPONENT WITH AGITATION - A method of forming a cast component includes at least partially surrounding an investment mold in a heat-insulating packing material, feeding a molten alloy into the investment mold to provide a filled investment mold, and agitating the filled investment mold while solidifying the molten alloy. | 08-04-2011 |
20110233378 | DIE INSERTS FOR DIE CASTING - An apparatus for casting material has a die for receiving a compressive force, the die having a shaped-opening for receiving a die insert. The die insert has an exterior shape that is adapted to cooperate with and be received in the opening such that compressive forces impinging upon the die are focused upon the die insert such that tensile forces within the die and impinging upon the die insert are minimized. | 09-29-2011 |
20120043046 | PROCESS FOR CASTING COLUMNAR GRAIN AIRFOIL WITH PREFERENTIAL PRIMARY ORIENTATION - A molding process utilizes a seed with a columnar grain structure for defining a desired grain structure in a completed casting. The seed is received within a seed cavity of a mold. The molten material adopts the orientation of the columns defined within the seed during solidification to form a completed molded article having a desired columnar grain structure. | 02-23-2012 |
20120110813 | DIE CASTING SYSTEM AND METHOD UTILIZING SACRIFICIAL CORE - A method for die casting a component includes inserting at least one sacrificial core into a die cavity of a die comprised of a plurality of die elements. Molten metal is injected into the die cavity. The molten metal is solidified within the die cavity to form the component. The plurality of die elements are disassembled from the component, and the at least one sacrificial core is destructively removed from the component. | 05-10-2012 |
20120111521 | DIE CASTING OF COMPONENT HAVING INTEGRAL SEAL - A method of die casting a component having an integral seal includes defining a first portion of a die cavity of a die to include an open cell structure. A second portion of the die is defined without the open cell structure. Molten metal is injected into the die cavity, and the molten metal is solidified within the die cavity to form the component having the integral seal. | 05-10-2012 |
20120111522 | DIE CASTING SYSTEM MACHINE CONFIGURATIONS - A die casting system includes a die, a shot tube and a shot tube plunger. The die casting system is positioned relative to a surface. The die includes a plurality of die components that define a die cavity. The shot tube is in fluid communication with the die cavity. The shot tube plunger is moveable within the shot tube to communicate molten metal into the die cavity. Each of the die, the shot tube and the shot tube plunger are inclined at an angle relative to the surface during injection of the molten metal into the die cavity. | 05-10-2012 |
20120111523 | MELTING UNIT FOR A DIE CASTING SYSTEM - A die casting system includes a die, a shot tube, a shot tube plunger and a melting unit. The die includes a plurality of die components that define a die cavity. The shot tube is in fluid communication with the die cavity. A shot tube plunger is moveable within the shot tube to communicate a charge of material into the die cavity. The melting unit is positioned relative to the die and includes a bottom portion having an opening for selectively releasing a charge of material through the bottom portion. | 05-10-2012 |
20120111524 | SHOT TUBE PLUNGER FOR A DIE CASTING SYSTEM - A shot tube plunger for a die casting system includes a first face, an opposing second face and an outer surface disposed between said first face and said opposing second face. A channel circumferentially extends about the outer surface. The channel is operable to receive a portion of a charge of material introduced into the die casting system. | 05-10-2012 |
20120175075 | Preformed ceramic seed well for single crystal starter seed - A method of creating an article from investment casting includes forming a ceramic seed well, heating the ceramic seed well to form a hardened ceramic seed well, attaching a meltable pattern to the hardened ceramic seed well, coating the hardened ceramic seed well and the meltable pattern with hardenable ceramic material, heating the hardenable ceramic material to melt the meltable pattern, removing the meltable pattern from the hardenable ceramic material, firing the hardenable ceramic material to form a ceramic mold having a cavity, placing a seed within the hardened ceramic seed well, and pouring molten metal into the hardened ceramic seed well and the cavity. The cavity of the ceramic mold is in communication with the hardened ceramic seed well. | 07-12-2012 |
20120211193 | DIE CASTING SYSTEM AND CELL - A die casting system includes a die, a shot tube, a melting system and a vacuum system. The die includes a plurality of die components that define a die cavity. The shot tube is in fluid communication with the die cavity and is operable to deliver a charge of material to the die cavity. The melting system is positioned adjacent to the die and includes an alloy loader, a melting unit and a crucible. The vacuum system defines a first chamber and a second chamber separated from the first chamber by an isolation valve. The melting system is disposed within the first chamber, and the die is disposed within the second chamber. | 08-23-2012 |
20130025810 | RAPID MANUFACTURING METHOD - A rapid manufacturing method includes forming tooling in a rapid manufacturing process. The tooling is coated with a conductive material. | 01-31-2013 |
20130026338 | RAPID CASTING ARTICLE MANUFACTURING - A method of manufacturing a casting article for use in a casting process includes rapidly forming the casting article out of a metallic material. A ceramic coating is applied to an exterior surface of the casting article. | 01-31-2013 |
20130081775 | METHOD AND SYSTEM FOR DIE CASTING A HYBRID COMPONENT - A method for die casting a hybrid component includes defining a cavity within a die element of a die and inserting a spar into the cavity. Molten metal is injected into the die element. The molten metal is solidified within the cavity to cast the hybrid component. The spar establishes an internal structure of the hybrid component. The spar includes a high melting temperature material that defines a first melting temperature greater than a second melting temperature of the molten metal. | 04-04-2013 |
20130115476 | METAL CASTING APPARATUS, CAST WORK PIECE AND METHOD THEREFOR - A metal casting apparatus includes a feeder for providing a molten metallic material. A mold includes a sprue and a component cavity. The sprue is arranged to receive the molten metallic material from the feeder and the component cavity is arranged to receive the molten metallic material from the sprue. A starter is arranged adjacent the component cavity and is operable to induce a first grain orientation upon solidification of the molten metallic material. The sprue includes an aborter that is arranged to induce a second grain orientation upon solidification of the molten metallic material. | 05-09-2013 |
20130171020 | HIGH TEMPERATURE DIRECTIONALLY SOLIDIFIED AND SINGLE CRYSTAL DIE CASTING - A high-temperature die casting apparatus comprises a die and a chiller. The die has a first die plate and a second die plate with respective first and second recesses defining a main part cavity and gating. The apparatus can be used for die casting metal alloys having a melting temperature of at least about 1500° F. (about 815° C.). | 07-04-2013 |
20140079542 | CASTING OF THIN WALL HOLLOW AIRFOIL SECTIONS - A casting mold assembly comprises an airfoil defining section and a casting core. The airfoil defining section includes an outer mold wall and a direct-shelled inner mold wall. The direct-shelled inner mold wall is disposed within a forward chordwise portion of the airfoil defining section. The direct-shelled inner mold wall includes an aft end having an external radius measuring more than about 0.075 in. (1.9 mm). The casting core is secured within an aft chordwise portion of the airfoil defining section, and includes an aft end with an external radius measuring less than about 0.075 in. (1.9 mm). A cast component and a method for making the casting mold assembly are also disclosed. | 03-20-2014 |
20140205493 | HIGH TEMPERATURE DIRECTIONALLY SOLIDIFIED AND SINGLE CRYSTAL DIE CASTING - A high-temperature die casting die includes a first die plate with a first recess and a second die plate with a second recess, the first and second recesses defining a main part cavity and gating. A grain selector is in fluid communication with the main cavity, and an in situ zone refining apparatus is adapted to apply a localized thermal gradient to at least one of the first and second die plates. The localized thermal gradient and the at least one die plate are movable relative to each other so as to apply the localized thermal gradient along a first direction extending from the grain selector longitudinally across the main part cavity. | 07-24-2014 |
20140338854 | DIE CASTING SYSTEM AND METHOD UTILIZING SACRIFICIAL CORE - A method for die casting a component includes inserting at least one sacrificial core into a die cavity of a die comprised of a plurality of die elements. Molten metal is injected into the die cavity. The molten metal is solidified within the die cavity to form the component. The plurality of die elements are disassembled from the component, and the at least one sacrificial core is destructively removed from the component. | 11-20-2014 |
20150060002 | DIE CASTING SYSTEM AND CELL - A method of manufacturing a component in a die casting cell that includes a die casting system according to an exemplary aspect of the present disclosure includes, among other things, isolating a first chamber from a second chamber of the die casting system, melting a charge of material in the first chamber, sealing the second chamber relative to the first chamber, and simultaneously injecting the charge of material within the second chamber to cast the component and melting a second charge of material within the first chamber. | 03-05-2015 |
20150075745 | Casting Molds, Manufacture and Use Methods - A casting mold ( | 03-19-2015 |