EP2759359B1 - Quasi self-destructive core for investment casting - Google Patents
Quasi self-destructive core for investment casting Download PDFInfo
- Publication number
- EP2759359B1 EP2759359B1 EP13194178.3A EP13194178A EP2759359B1 EP 2759359 B1 EP2759359 B1 EP 2759359B1 EP 13194178 A EP13194178 A EP 13194178A EP 2759359 B1 EP2759359 B1 EP 2759359B1
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- structural element
- core
- composite core
- slurry
- preform
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- 238000005495 investment casting Methods 0.000 title claims description 26
- 239000002131 composite material Substances 0.000 claims description 34
- 239000000463 material Substances 0.000 claims description 32
- 239000002002 slurry Substances 0.000 claims description 26
- 238000000034 method Methods 0.000 claims description 20
- 239000000919 ceramic Substances 0.000 claims description 18
- 239000002184 metal Substances 0.000 claims description 7
- 229910052751 metal Inorganic materials 0.000 claims description 7
- 239000011888 foil Substances 0.000 claims description 6
- 239000002245 particle Substances 0.000 claims description 6
- 238000010304 firing Methods 0.000 claims description 5
- 238000004519 manufacturing process Methods 0.000 claims description 5
- 230000006835 compression Effects 0.000 claims description 3
- 238000007906 compression Methods 0.000 claims description 3
- 239000000155 melt Substances 0.000 claims 1
- 238000005266 casting Methods 0.000 description 12
- 230000015572 biosynthetic process Effects 0.000 description 4
- 230000002787 reinforcement Effects 0.000 description 3
- 238000007711 solidification Methods 0.000 description 3
- 230000008023 solidification Effects 0.000 description 3
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 2
- 239000000956 alloy Substances 0.000 description 2
- 229910045601 alloy Inorganic materials 0.000 description 2
- 230000015556 catabolic process Effects 0.000 description 2
- 239000012530 fluid Substances 0.000 description 2
- 238000002347 injection Methods 0.000 description 2
- 239000007924 injection Substances 0.000 description 2
- 230000013011 mating Effects 0.000 description 2
- 239000010453 quartz Substances 0.000 description 2
- 238000007528 sand casting Methods 0.000 description 2
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N silicon dioxide Inorganic materials O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 2
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 1
- 229910000831 Steel Inorganic materials 0.000 description 1
- 230000004075 alteration Effects 0.000 description 1
- 238000005219 brazing Methods 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 229910052802 copper Inorganic materials 0.000 description 1
- 239000010949 copper Substances 0.000 description 1
- 230000001419 dependent effect Effects 0.000 description 1
- 239000003365 glass fiber Substances 0.000 description 1
- 239000007769 metal material Substances 0.000 description 1
- 150000002739 metals Chemical class 0.000 description 1
- 229910052759 nickel Inorganic materials 0.000 description 1
- 238000010120 permanent mold casting Methods 0.000 description 1
- 238000003908 quality control method Methods 0.000 description 1
- 239000011347 resin Substances 0.000 description 1
- 229920005989 resin Polymers 0.000 description 1
- 239000000243 solution Substances 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
- 238000004804 winding Methods 0.000 description 1
Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/10—Cores; Manufacture or installation of cores
Definitions
- Exemplary embodiments of the invention generally relate to investment casting, and more particularly, to a core for forming a passage in an investment casting mold.
- Investment casting is a commonly used technique for forming metallic components having complex shapes and geometries, especially hollow components such as those used in aerospace applications for example.
- the production of an investment cast part generally involves producing a ceramic casting mold having an outer ceramic shell with an inside surface corresponding to the shape of the part, and one or more ceramic cores positioned within the outer ceramic shell, corresponding to interior passages to be formed within the part.
- Molten alloy is introduced into the ceramic casting mold and is then allowed to cool and to harden.
- the outer ceramic shell and ceramic core(s) are then removed to reveal a cast part having a desired external shape and hollow interior passages in the shape of the ceramic core(s).
- CSIC controlled solidification investment casting
- sand casting In comparison to other processes, for example sand casting or permanent mold casting, investment casting provides flexibility while maintaining tight tolerances.
- controlled solidification investment casting CSIC
- CSIC uses rapid directional cooling to enhance microstructure and mechanical properties.
- CSIC therefore, may be useful for an expanded range of applications, particularly in the aerospace industry.
- investment casting is limited by the design of passages within the mold. Unlike a sand core used in a sand casting process, the ceramic cores used in CSIC are difficult to remove or destroy without affecting the molded part. As a result, the process of designing passages severely restricts the use of CSIC for applications requiring complex cored passages.
- JP S57-085638 describes a hollow tube made of metal is formed by winding up a wire spirally, and the outer periphery of the tube is covered with a covering material composed of a low heat conductivity brittle material, such as ceramics, etc.
- the hollow tube 8 is used as a core grid and castings are made after the hollow tube is installed throughout the mold. After the casting is completed, a low temperature fluid, such as water, air, etc., is poured into said hollow tube and a large temperature difference is generated between an inner wall and an outer wall of the covering material, and then, the covering material is self-broken by strains generated by the internal stress due to the temperature difference. After the covering material is broken, said hollow tube is pulled out and, at the same time, the covering material is removed.
- a low temperature fluid such as water, air, etc.
- It aims to ease removal of a covering material, by using a hollow core grid whose outer periphery covered with the prescribed covering material and disintegrating the covering material after a molten metal is poured into the mold by the difference in temperatures of the core grid and the casting after a cold fluid is passed through the hollow section.
- U.S. 3,066,365 describes a destructible reinforced sand core for meta! casting used for casting metals and more particularly, it relates to a fabricated core reinforced with destructible, resin bonded glass fiber filaments.
- the reinforcement structure for cores has such character to provide adequate reinforcement of the core during formation of the core, placement of the core in the mold, and during the casting process, said reinforcement structure also being of such character that it will fracture or otherwise become sufficiently deformed during the shaking process of core removal that it is readily removable by means of the shaking process.
- U.S. 4,905,750 describes forming a wax or sacrificial pattern for investment castings in which the interior ceramic reinforced passageway forming elements are reinforced with a metallic wire, and sheathed in a quartz material is disclosed. Thereafter the wire and quartz serve as a reinforced core around which the ceramic is molded to the configuration of the passageway, and in addition containing the positioning elements for mating engagement with the wax injection die at each end of the passage forming part.
- Its method involves first determining the passage locations, and thereafter forming a reinforced passage ceramic forming member to be positioned interiorly of the pattern.
- the wax injection die is formed with mating elements to support the ceramic passage forming members.
- the mold is filled with sequential layers of ceramic, and fired. Once the mold is fired and it is totally de-waxed, it is then available for investment casting in the state-of-the-art fashion by pouring or teeming the metal into the investment casting.
- a composite core for making a passage in an investment casting mold comprises a hollow structural element comprising a metal, which is a coiled wire, such that the structural element behaves in a manner similar to a tensile or compression spring, and configured to deform when a force is applied to an end thereof; a core element adjacent an interior surface of a generally hollow structural element comprising a metallic mesh or foil; and a rigid shell element formed by curing a plurality of layers of a slurry comprising particles of varying sizes, about the structural element, the rigid shell element extending beyond an interior surface from adjacent the core element to an exterior surface of the structural element, the shell element being configured to shatter when the structural element deforms.
- the rigid shell element may be integrally formed with the structural element.
- the structural element comprises a coiled wire.
- a material of the structural element may be substantially identical to a material of a component to be formed from the investment casting mold.
- the structural element may be generally the same size as the passage being formed.
- the shell element is formed by arranging multiple layers of slurry having particles of varying sizes, and curing the layers of slurry to form the rigid shell element.
- a material of the slurry may be substantially identical to a material of the investment casting mold.
- the material of the slurry may be generally ceramic.
- a method for manufacturing a composite core for forming a passage in an investment casting mold including arranging a core element adjacent an interior surface of a generally hollow structural element to form a preform, the structural element being a coiled wire; layering the slurry, having particles of varying sizes about the structural element of the preform, an end of the structural element being exposed; and applying heat to the preform to form the slurry into the rigid shell element.
- Particular embodiments may include any of the following optional features, alone or in combination:
- the slurry is cured into a rigid shell element during the firing of the preform.
- the core element may melt away from the structural element during the firing of the preform.
- the slurry may extend from adjacent a surface of the core element to beyond an outer surface of the structural element.
- a method of forming a passage in a cast component including arranging a composite core into an interior of a mold. Material of the component is then poured into the mold. The material is cured to form the component. A force is then applied to an exposed portion of the composite core such that the composite core deforms inside the component.
- the composite core may include a structural element and a rigid outer shell element formed about the structural element such that deformation of the structural element causes the shell element to break.
- the composite core 20 When inserted into a mold (not shown), the composite core 20 includes a generally hollow structural element 40 and a shell element 60 arranged about the exterior 46 of the structural element 40.
- the structural element 40 is configured to deform, and therefore break the shell element 60 coupled thereto, when a force is applied to an end 42 ( FIG. 2 ) of the structural element 40.
- the composite core 20 is formed using a preform 30, illustrated in more detail in FIG. 2 .
- the preform 30 includes the generally hollow structural element 40 as well as a core element 50 positioned adjacent the interior surface 44 of the structural element.
- the structural element 40 may be pre-formed and the core element 50 inserted into the hollow center 47 of the structural element 40, or alternatively, the structural element 40 may be formed around the exterior of the core element 50.
- An example of the structural element 40 is the general size of a passage being formed within an investment casting mold.
- the material used to form the structural element 40 is selected based on the material of the component being cast.
- the material of the structural element 40 may be the same alloy as the component being cast.
- Exemplary metallic materials include, but are not limited to, steel, copper, and nickel for example.
- the structural element 40 is fabricated from a coiled wire 48 such that the structural element 40 behaves in a manner similar to a tensile or compression spring.
- the specifications of the wire 48 are selected to facilitate contact between the structural element 40 and the core element 50, as well as the ultimate breakdown of the composite core 20.
- the cross-section of the wire 48 may be any of a variety of shapes, such as circular, square, triangular, or trapezoidal for example, and the coils of the wire 48 need not be evenly spaced as shown.
- Considerations for the strength and ductility of the structural element 40 include the ability of the structural element 40 to support itself once coupled to the core element 50, the ability of the structural element 40 to support the composite core 20 once the shell element 60 is formed, and the ability of the structural element 40 to deform when a force is applied thereto.
- the core element 50 acts as a base to support the outer shell element 60 as it is formed about the structural element 40.
- the core element 50 is made from a material configured to melt during the formation of the composite core 20, prior to the casting process, or during the casting process.
- the core element 50 is a wax core, the contour of which is substantially similar to a passage being formed in a mold.
- the core element 50 is a metallic mesh or foil, for example made from the same material as the working metal to be poured into the investment casting mold.
- the metallic mesh or foil 50 is bonded to the interior surface 44 of the structural element 40, such as through a brazing process for example.
- the gauge of the foil or mesh 50 is selected to support the shell element 60 as it is formed about the structural element 40. Once the metallic mesh or foil 50 and the structural element 40 are coupled, the contour of the preform 30 may be altered to a desired shape.
- the outer shell element 60 is formed, for example through a shelling process. As illustrated in FIG. 4 , the preform 30 is coated with a slurry 62 having particles of varying sizes.
- the material of the slurry 62 used to form the outer shell 60 is substantially identical to the material used to form the investment casting mold, such as ceramic for example.
- the material of the slurry 62 may be modified to facilitate breakdown of the outer shell 60 when a force is applied to the structural element 40.
- the slurry 62 is arranged in a plurality of layers extending outwardly from the surface 52 of the core element 50 to at least the outer surface 46 of the structural element 40 such that the structural element 40 and the shell element 60 are integrally formed.
- the surface 52 of the core element 50 may be dipped in the slurry 62 before being inserted into the structural element 40, to aid in the formation of an inner surface of the shell element 60.
- slurry 62 is positioned about the structural element 40 such that when the composite core 20 is formed, the shell element 60 extends beyond both the inner diameter 44 and the outer diameter 46 of the structural element 40 (see FIG. 1 ).
- the slurry 62 is hardened, such as by firing the preform 30 in an oven or kiln for example.
- Heat causes the slurry 62 to strengthen and solidify into a cured, rigid, shell element 60.
- the core element 50 is designed to melt, or otherwise degrade during the making of the composite core 20, or during the formation of the finished component. Therefore, application of heat transforms the preform 30 to a composite core 20, having a generally hollow cross section that allows the structural element 40 and the shell element 60 to be easily removed.
- the outer surface 64 of the shell element 60 may be substantially uniform, or alternatively, may include slight variations, such as waves or grooves for example.
- a component 80 formed using an investment casting mold and at least one composite core 20 is illustrated.
- a portion of the shell element 60 is broken to reveal an end 42 of the structural element 40.
- a force is then applied to the exposed end 42, causing the structural element to deform 40.
- the shell element 60 is formed about the structural element 40, deformation thereof causes the brittle shell element 60 to shatter and break away from coiled wire 48 of the structural element 40.
- the pieces of the shell element 60 and the structural element 40 may then be easily removed from the passage 82 of the component 80.
- the composite core 20 may be constructed to create a complex cored passage within an investment casting mold, thereby expanding the range of applications to which controlled solidification investment casting (CSIC) may be applied. Further, by incorporating waves or grooves into the outer surface 64 of the shell element 60, the passage 82 can have specific patterns such as rifling. The rapid and directional solidification of the investment casting process will result in high quality castings having enhanced microstructures. Because a significant portion of the CSIC process is automated, more stringent quality control measures may be implemented to improve and stabilize the casting process. Forming parts that were previously too complex using a CSIC process will reduce both scrap rates and production cycle time.
- CSIC controlled solidification investment casting
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- Molds, Cores, And Manufacturing Methods Thereof (AREA)
Description
- Exemplary embodiments of the invention generally relate to investment casting, and more particularly, to a core for forming a passage in an investment casting mold.
- Investment casting is a commonly used technique for forming metallic components having complex shapes and geometries, especially hollow components such as those used in aerospace applications for example. The production of an investment cast part generally involves producing a ceramic casting mold having an outer ceramic shell with an inside surface corresponding to the shape of the part, and one or more ceramic cores positioned within the outer ceramic shell, corresponding to interior passages to be formed within the part. Molten alloy is introduced into the ceramic casting mold and is then allowed to cool and to harden. The outer ceramic shell and ceramic core(s) are then removed to reveal a cast part having a desired external shape and hollow interior passages in the shape of the ceramic core(s).
- In comparison to other processes, for example sand casting or permanent mold casting, investment casting provides flexibility while maintaining tight tolerances. In particular, controlled solidification investment casting (CSIC) uses rapid directional cooling to enhance microstructure and mechanical properties. CSIC, therefore, may be useful for an expanded range of applications, particularly in the aerospace industry. However, investment casting is limited by the design of passages within the mold. Unlike a sand core used in a sand casting process, the ceramic cores used in CSIC are difficult to remove or destroy without affecting the molded part. As a result, the process of designing passages severely restricts the use of CSIC for applications requiring complex cored passages.
-
JP S57-085638 -
U.S. 3,066,365 describes a destructible reinforced sand core for meta! casting used for casting metals and more particularly, it relates to a fabricated core reinforced with destructible, resin bonded glass fiber filaments. The reinforcement structure for cores has such character to provide adequate reinforcement of the core during formation of the core, placement of the core in the mold, and during the casting process, said reinforcement structure also being of such character that it will fracture or otherwise become sufficiently deformed during the shaking process of core removal that it is readily removable by means of the shaking process. -
U.S. 4,905,750 describes forming a wax or sacrificial pattern for investment castings in which the interior ceramic reinforced passageway forming elements are reinforced with a metallic wire, and sheathed in a quartz material is disclosed. Thereafter the wire and quartz serve as a reinforced core around which the ceramic is molded to the configuration of the passageway, and in addition containing the positioning elements for mating engagement with the wax injection die at each end of the passage forming part. Its method involves first determining the passage locations, and thereafter forming a reinforced passage ceramic forming member to be positioned interiorly of the pattern. The wax injection die is formed with mating elements to support the ceramic passage forming members. Thereafter the mold is filled with sequential layers of ceramic, and fired. Once the mold is fired and it is totally de-waxed, it is then available for investment casting in the state-of-the-art fashion by pouring or teeming the metal into the investment casting. - Aspects of the invention may address one or more shortcomings of the art with solution(s) as set forth in the independent claims and refinements as recited in the dependent claims.
- According to one embodiment of the invention, a composite core for making a passage in an investment casting mold is provided. The composite core comprises a hollow structural element comprising a metal, which is a coiled wire, such that the structural element behaves in a manner similar to a tensile or compression spring, and configured to deform when a force is applied to an end thereof; a core element adjacent an interior surface of a generally hollow structural element comprising a metallic mesh or foil; and a rigid shell element formed by curing a plurality of layers of a slurry comprising particles of varying sizes, about the structural element, the rigid shell element extending beyond an interior surface from adjacent the core element to an exterior surface of the structural element, the shell element being configured to shatter when the structural element deforms.
- Particular embodiments may include any of the following optional features, alone or in combination:
The rigid shell element may be integrally formed with the structural element. - The structural element comprises a coiled wire.
- A material of the structural element may be substantially identical to a material of a component to be formed from the investment casting mold.
- The structural element may be generally the same size as the passage being formed.
- The shell element is formed by arranging multiple layers of slurry having particles of varying sizes, and curing the layers of slurry to form the rigid shell element.
- A material of the slurry may be substantially identical to a material of the investment casting mold.
- The material of the slurry may be generally ceramic.
- According to yet another embodiment of the invention, a method for manufacturing a composite core for forming a passage in an investment casting mold is provided including arranging a core element adjacent an interior surface of a generally hollow structural element to form a preform, the structural element being a coiled wire; layering the slurry, having particles of varying sizes about the structural element of the preform, an end of the structural element being exposed; and applying heat to the preform to form the slurry into the rigid shell element.
- Particular embodiments may include any of the following optional features, alone or in combination:
The slurry is cured into a rigid shell element during the firing of the preform. - The core element may melt away from the structural element during the firing of the preform.
- The slurry may extend from adjacent a surface of the core element to beyond an outer surface of the structural element.
- According to another embodiment, a method of forming a passage in a cast component is provided including arranging a composite core into an interior of a mold. Material of the component is then poured into the mold. The material is cured to form the component. A force is then applied to an exposed portion of the composite core such that the composite core deforms inside the component.
- Particular embodiments may include any of the following optional features, alone or in combination:
The composite core may include a structural element and a rigid outer shell element formed about the structural element such that deformation of the structural element causes the shell element to break. - The subject matter, which is regarded as the invention, is particularly pointed out and distinctly claimed in the claims at the conclusion of the specification. The foregoing and other features, and advantages of the invention are apparent from the following detailed description taken in conjunction with the accompanying drawings in which:
-
FIG. 1 is a cross-sectional view of a composite core according to an embodiment of the invention; -
FIG. 2 is a cross-sectional view of a preform according to an embodiment of the invention; -
FIG. 3 is side view of a structural element of the preform according to an embodiment of the invention; -
FIG. 4 is a perspective view of a preform including layers of slurry according to an embodiment of the invention; and -
FIG. 5 is a cross-sectional view of a component formed from an investment casting mold having a passage formed by a composite core according to an embodiment of the invention. - The detailed description explains embodiments of the invention, together with advantages and features, by way of example with reference to the drawings.
- With reference now to
FIG. 1 , a cross-section of acomposite core 20 for forming a passage in an investment casting mold is illustrated. When inserted into a mold (not shown), thecomposite core 20 includes a generally hollowstructural element 40 and ashell element 60 arranged about theexterior 46 of thestructural element 40. Thestructural element 40 is configured to deform, and therefore break theshell element 60 coupled thereto, when a force is applied to an end 42 (FIG. 2 ) of thestructural element 40. - The
composite core 20 is formed using apreform 30, illustrated in more detail inFIG. 2 . Thepreform 30 includes the generally hollowstructural element 40 as well as acore element 50 positioned adjacent theinterior surface 44 of the structural element. Thestructural element 40 may be pre-formed and thecore element 50 inserted into thehollow center 47 of thestructural element 40, or alternatively, thestructural element 40 may be formed around the exterior of thecore element 50. - An example of the
structural element 40, shown inFIG. 3 , is the general size of a passage being formed within an investment casting mold. The material used to form thestructural element 40 is selected based on the material of the component being cast. For example, the material of thestructural element 40 may be the same alloy as the component being cast. Exemplary metallic materials include, but are not limited to, steel, copper, and nickel for example. In the illustrated embodiment, thestructural element 40 is fabricated from a coiledwire 48 such that thestructural element 40 behaves in a manner similar to a tensile or compression spring. The specifications of thewire 48 are selected to facilitate contact between thestructural element 40 and thecore element 50, as well as the ultimate breakdown of thecomposite core 20. As a result, the cross-section of thewire 48 may be any of a variety of shapes, such as circular, square, triangular, or trapezoidal for example, and the coils of thewire 48 need not be evenly spaced as shown. Considerations for the strength and ductility of thestructural element 40 include the ability of thestructural element 40 to support itself once coupled to thecore element 50, the ability of thestructural element 40 to support thecomposite core 20 once theshell element 60 is formed, and the ability of thestructural element 40 to deform when a force is applied thereto. - The
core element 50 acts as a base to support theouter shell element 60 as it is formed about thestructural element 40. Thecore element 50 is made from a material configured to melt during the formation of thecomposite core 20, prior to the casting process, or during the casting process. In one embodiment, thecore element 50 is a wax core, the contour of which is substantially similar to a passage being formed in a mold. In another embodiment, thecore element 50 is a metallic mesh or foil, for example made from the same material as the working metal to be poured into the investment casting mold. The metallic mesh orfoil 50 is bonded to theinterior surface 44 of thestructural element 40, such as through a brazing process for example. The gauge of the foil ormesh 50 is selected to support theshell element 60 as it is formed about thestructural element 40. Once the metallic mesh orfoil 50 and thestructural element 40 are coupled, the contour of thepreform 30 may be altered to a desired shape. - After the
preform 30 is assembled, theouter shell element 60 is formed, for example through a shelling process. As illustrated inFIG. 4 , thepreform 30 is coated with aslurry 62 having particles of varying sizes. In one embodiment, the material of theslurry 62 used to form theouter shell 60 is substantially identical to the material used to form the investment casting mold, such as ceramic for example. Alternatively, the material of theslurry 62 may be modified to facilitate breakdown of theouter shell 60 when a force is applied to thestructural element 40. Theslurry 62 is arranged in a plurality of layers extending outwardly from thesurface 52 of thecore element 50 to at least theouter surface 46 of thestructural element 40 such that thestructural element 40 and theshell element 60 are integrally formed. In one embodiment, for example where thecore element 50 is a wax core, thesurface 52 of thecore element 50 may be dipped in theslurry 62 before being inserted into thestructural element 40, to aid in the formation of an inner surface of theshell element 60. As a result,slurry 62 is positioned about thestructural element 40 such that when thecomposite core 20 is formed, theshell element 60 extends beyond both theinner diameter 44 and theouter diameter 46 of the structural element 40 (seeFIG. 1 ). - After layering the
slurry 62 about thestructural element 40, theslurry 62 is hardened, such as by firing thepreform 30 in an oven or kiln for example. Heat causes theslurry 62 to strengthen and solidify into a cured, rigid,shell element 60. Thecore element 50 is designed to melt, or otherwise degrade during the making of thecomposite core 20, or during the formation of the finished component. Therefore, application of heat transforms thepreform 30 to acomposite core 20, having a generally hollow cross section that allows thestructural element 40 and theshell element 60 to be easily removed. When thecomposite core 20 is formed, theouter surface 64 of theshell element 60 may be substantially uniform, or alternatively, may include slight variations, such as waves or grooves for example. - Referring now to
FIG. 5 , acomponent 80 formed using an investment casting mold and at least onecomposite core 20 is illustrated. To remove thecomposite core 20 from apassage 82 of thecomponent 80, a portion of theshell element 60 is broken to reveal anend 42 of thestructural element 40. A force is then applied to the exposedend 42, causing the structural element to deform 40. Because theshell element 60 is formed about thestructural element 40, deformation thereof causes thebrittle shell element 60 to shatter and break away from coiledwire 48 of thestructural element 40. The pieces of theshell element 60 and thestructural element 40 may then be easily removed from thepassage 82 of thecomponent 80. - The
composite core 20 may be constructed to create a complex cored passage within an investment casting mold, thereby expanding the range of applications to which controlled solidification investment casting (CSIC) may be applied. Further, by incorporating waves or grooves into theouter surface 64 of theshell element 60, thepassage 82 can have specific patterns such as rifling. The rapid and directional solidification of the investment casting process will result in high quality castings having enhanced microstructures. Because a significant portion of the CSIC process is automated, more stringent quality control measures may be implemented to improve and stabilize the casting process. Forming parts that were previously too complex using a CSIC process will reduce both scrap rates and production cycle time. - While the invention has been described in detail in connection with only a limited number of embodiments, it should be readily understood that the invention is not limited to such disclosed embodiments. Rather, the invention can be modified to incorporate any number of variations, alterations, substitutions or equivalent arrangements not heretofore described, but which are commensurate with the spirit and scope of the invention. Additionally, while various embodiments of the invention have been described, it is to be understood that aspects of the invention may include only some of the described embodiments. Accordingly, the invention is not to be seen as limited by the foregoing description, but is only limited by the scope of the appended claims.
Claims (11)
- A composite core (20) for making a passage (82) in an investment casting mold, the composite core (20) comprising:a hollow structural element (40) comprising a metal, which is a coiled wire (48), such that the structural element (40) behaves in a manner similar to a tensile or compression spring, and configured to deform when a force is applied to an end thereof;a core element (50) adjacent an interior surface (44) of the hollow structural element (40) comprising a metallic mesh or foil; anda rigid shell element (60) formed by curing a plurality of layers of a slurry (62) comprising particles of varying sizes, about the structural element (40), characterized in that the rigid shell element (60) extending beyond an interior surface (44) from adjacent the core element (50) to an exterior surface (46) of the structural element (40), the shell element (60) being configured to shatter when the structural element (40) deforms.
- The composite core (20) according to claim 1, wherein the rigid shell element (60) is integrally formed with the structural element (40).
- The composite core (20) according to claim 1 or 2, wherein a material of the structural element (40) is identical to a material of a component to be formed from the investment casting mold.
- The composite core (20) according to any of claims 1 to 3, wherein the structural element (40) is the same size as the passage being formed.
- The composite core (20) according to claim 1, wherein a material of the slurry (62) is identical to a material of the investment casting mold.
- The composite core (20) according to claim 5, wherein the material of the slurry (62) is ceramic.
- A method for manufacturing the composite core (20) of any one of the preceding claims, the method comprising:arranging a core element (50) adjacent an interior surface (44) of the hollow structural element (40) to form a preform (30), the structural element (40) being a coiled wire;layering the slurry (62), having particles of varying sizes about the structural element (40) of the preform (30), an end (42) of the structural element (40) being exposed; andapplying heat to the preform (30) to form the slurry (62) into the rigid shell element (60).
- The method of claim 7, wherein the slurry (62) cures into a rigid shell element (60) during the firing of the preform (30).
- The method of claim 7 or 8, wherein the core element melts (50) away from the structural element (40) during the firing of the preform (30).
- The method of any of claims 7 to 9, wherein the slurry (62) extends from adjacent the surface (52) of the core element (50) to beyond the exterior surface (46) of the structural element (40).
- A method for forming a passage (82) in a cast component comprising:manufacturing the composite core (20) according to claim 1;arranging the composite core (20) into an interior of a mold;pouring material of the component into the mold;curing the material to form the component;applying a force to an exposed portion of the composite core (20) such that the composite core (20) deforms inside the component.
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US13/747,653 US20140202650A1 (en) | 2013-01-23 | 2013-01-23 | Quasi self-destructive core for investment casting |
Publications (3)
Publication Number | Publication Date |
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EP2759359A2 EP2759359A2 (en) | 2014-07-30 |
EP2759359A3 EP2759359A3 (en) | 2018-01-03 |
EP2759359B1 true EP2759359B1 (en) | 2020-06-17 |
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EP13194178.3A Active EP2759359B1 (en) | 2013-01-23 | 2013-11-23 | Quasi self-destructive core for investment casting |
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US (2) | US20140202650A1 (en) |
EP (1) | EP2759359B1 (en) |
Families Citing this family (12)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US10099284B2 (en) | 2015-12-17 | 2018-10-16 | General Electric Company | Method and assembly for forming components having a catalyzed internal passage defined therein |
US10099276B2 (en) | 2015-12-17 | 2018-10-16 | General Electric Company | Method and assembly for forming components having an internal passage defined therein |
US9987677B2 (en) | 2015-12-17 | 2018-06-05 | General Electric Company | Method and assembly for forming components having internal passages using a jacketed core |
US10099283B2 (en) | 2015-12-17 | 2018-10-16 | General Electric Company | Method and assembly for forming components having an internal passage defined therein |
US10118217B2 (en) | 2015-12-17 | 2018-11-06 | General Electric Company | Method and assembly for forming components having internal passages using a jacketed core |
US9968991B2 (en) | 2015-12-17 | 2018-05-15 | General Electric Company | Method and assembly for forming components having internal passages using a lattice structure |
US9579714B1 (en) | 2015-12-17 | 2017-02-28 | General Electric Company | Method and assembly for forming components having internal passages using a lattice structure |
US10137499B2 (en) | 2015-12-17 | 2018-11-27 | General Electric Company | Method and assembly for forming components having an internal passage defined therein |
US10046389B2 (en) * | 2015-12-17 | 2018-08-14 | General Electric Company | Method and assembly for forming components having internal passages using a jacketed core |
US10150158B2 (en) | 2015-12-17 | 2018-12-11 | General Electric Company | Method and assembly for forming components having internal passages using a jacketed core |
US10335853B2 (en) | 2016-04-27 | 2019-07-02 | General Electric Company | Method and assembly for forming components using a jacketed core |
US10286450B2 (en) | 2016-04-27 | 2019-05-14 | General Electric Company | Method and assembly for forming components using a jacketed core |
Family Cites Families (15)
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US2045556A (en) * | 1934-01-08 | 1936-06-23 | Gen Motors Corp | Collapsible molding core |
US2991520A (en) * | 1956-01-13 | 1961-07-11 | Howard Foundry Company | Cored passageway formation |
GB847033A (en) * | 1958-06-04 | 1960-09-07 | Foundry Services Int Ltd | Improvements in or relating to moulding processes and materials |
US3066365A (en) * | 1958-07-02 | 1962-12-04 | Pittsburgh Plate Glass Co | Destructible reinforced sand core for metal casting |
US3020615A (en) * | 1958-11-26 | 1962-02-13 | Alfred H Peters | Conduit molding form |
US3032842A (en) * | 1958-12-15 | 1962-05-08 | Dow Chemical Co | Method of making a fusible metallic core with woven fiber sleeve |
GB2006069A (en) * | 1977-10-15 | 1979-05-02 | Sterling Metals Ltd | Metal casting cores |
JPS591496B2 (en) * | 1980-11-13 | 1984-01-12 | 三協オイルレス工業株式会社 | Method for casting a casting having a hollow tubular part |
US4530722A (en) * | 1983-03-24 | 1985-07-23 | Harborchem, Inc. | Binder and refractory compositions and methods |
FR2625455B1 (en) * | 1987-12-30 | 1993-10-08 | Zenith Fonderie Sa | PROCESS AND DEVICE FOR PRODUCING MOLDED PARTS |
US4905750A (en) * | 1988-08-30 | 1990-03-06 | Amcast Industrial Corporation | Reinforced ceramic passageway forming member |
US5201357A (en) * | 1992-01-16 | 1993-04-13 | Cmi International, Inc. | Method for forming cored passageways within cast metal articles |
WO2012003439A1 (en) * | 2010-07-02 | 2012-01-05 | Mikro Systems, Inc. | Self supporting core-in-a-core for casting |
US8393381B2 (en) * | 2011-05-18 | 2013-03-12 | Pcc Airfoils, Inc. | Method of forming a cast metal article |
FR2975613B1 (en) * | 2011-05-25 | 2013-06-21 | Filtrauto | PROCESS FOR MANUFACTURING METAL FOAM PROVIDED WITH CONDUITS AND METALLIC FOAM THUS OBTAINED |
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2013
- 2013-01-23 US US13/747,653 patent/US20140202650A1/en not_active Abandoned
- 2013-11-23 EP EP13194178.3A patent/EP2759359B1/en active Active
-
2016
- 2016-02-23 US US15/051,311 patent/US20160243609A1/en not_active Abandoned
Non-Patent Citations (1)
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None * |
Also Published As
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EP2759359A3 (en) | 2018-01-03 |
US20160243609A1 (en) | 2016-08-25 |
US20140202650A1 (en) | 2014-07-24 |
EP2759359A2 (en) | 2014-07-30 |
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