EP3907018B1 - Thermal management in lost wax casting - Google Patents
Thermal management in lost wax casting Download PDFInfo
- Publication number
- EP3907018B1 EP3907018B1 EP21172009.9A EP21172009A EP3907018B1 EP 3907018 B1 EP3907018 B1 EP 3907018B1 EP 21172009 A EP21172009 A EP 21172009A EP 3907018 B1 EP3907018 B1 EP 3907018B1
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- EP
- European Patent Office
- Prior art keywords
- wax
- ceramic
- assembly
- ceramic mold
- wax assembly
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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Links
- 238000005495 investment casting Methods 0.000 title description 16
- 239000000919 ceramic Substances 0.000 claims description 95
- 238000000034 method Methods 0.000 claims description 48
- 238000005266 casting Methods 0.000 claims description 26
- 239000012768 molten material Substances 0.000 claims description 20
- 239000002002 slurry Substances 0.000 claims description 10
- 229910000831 Steel Inorganic materials 0.000 claims description 4
- 238000001035 drying Methods 0.000 claims description 4
- 239000010959 steel Substances 0.000 claims description 4
- 238000010304 firing Methods 0.000 claims description 2
- 239000002184 metal Substances 0.000 description 18
- 239000007787 solid Substances 0.000 description 6
- 238000007711 solidification Methods 0.000 description 6
- 230000008023 solidification Effects 0.000 description 6
- 244000044283 Toxicodendron succedaneum Species 0.000 description 4
- 230000007547 defect Effects 0.000 description 4
- 238000001816 cooling Methods 0.000 description 3
- 239000000463 material Substances 0.000 description 3
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 2
- 230000004888 barrier function Effects 0.000 description 2
- 238000004519 manufacturing process Methods 0.000 description 2
- 229910001233 yttria-stabilized zirconia Inorganic materials 0.000 description 2
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 1
- 238000005524 ceramic coating Methods 0.000 description 1
- 239000011153 ceramic matrix composite Substances 0.000 description 1
- 239000011248 coating agent Substances 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- 239000004020 conductor Substances 0.000 description 1
- 238000012864 cross contamination Methods 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 238000011065 in-situ storage Methods 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 239000002245 particle Substances 0.000 description 1
- 230000010076 replication Effects 0.000 description 1
- 239000000377 silicon dioxide Substances 0.000 description 1
- 238000005728 strengthening Methods 0.000 description 1
- 229910052845 zircon Inorganic materials 0.000 description 1
- GFQYVLUOOAAOGM-UHFFFAOYSA-N zirconium(iv) silicate Chemical compound [Zr+4].[O-][Si]([O-])([O-])[O-] GFQYVLUOOAAOGM-UHFFFAOYSA-N 0.000 description 1
Images
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C19/00—Components or accessories for moulding machines
- B22C19/04—Controlling devices specially designed for moulding machines
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C21/00—Flasks; Accessories therefor
- B22C21/12—Accessories
- B22C21/14—Accessories for reinforcing or securing moulding materials or cores, e.g. gaggers, chaplets, pins, bars
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C7/00—Patterns; Manufacture thereof so far as not provided for in other classes
- B22C7/02—Lost patterns
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/02—Sand moulds or like moulds for shaped castings
- B22C9/04—Use of lost patterns
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/02—Sand moulds or like moulds for shaped castings
- B22C9/04—Use of lost patterns
- B22C9/043—Removing the consumable pattern
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/08—Features with respect to supply of molten metal, e.g. ingates, circular gates, skim gates
- B22C9/082—Sprues, pouring cups
-
- 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
- B22C9/103—Multipart cores
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D15/00—Casting using a mould or core of which a part significant to the process is of high thermal conductivity, e.g. chill casting; Moulds or accessories specially adapted therefor
Definitions
- the embodiments herein relate to casting of materials and more specifically to thermal management in lost wax casting.
- Investment casting may include a wax part pattern of an article to be cast, which may be produced from a die mold.
- the component wax pattern may be connected with injected wax shapes on a wax assembly, which will typically possesses a pour-cup, down-sprue, wax in-gates, and then the component pattern itself.
- the wax tree, with the part patterns, is then coated with a ceramic slurry to form a ceramic shell over its surface.
- the wax assembly may then be withdrawn from the slurry and dried.
- the steps of coating and drying are repeated until a ceramic shell mold around the wax tree is of a sufficient thickness, which may depend on the weight of the cast assembly.
- the wax tree, with the ceramic shell is then placed in a furnace pressurized steam de-waxer vessel removes the wax from the inside of the ceramic mold.
- the ceramic mold is then placed into a furnace to heat and sinter the ceramic particles to strengthen the mold to enable the receipt of a certain volume of molten metal.
- the hardening may be in a separate thermal processing step.
- the ceramic mold is then ready for the casting of the part. Molten metal is poured into the pour-cup and passed through the sprue and ingates into the component cavity once defined by the wax assembly. After the metal has solidified, the ceramic shell is removed mechanically to reveal the metal components on the assembly. The cast components are then removed from the assembly, mechanically finished and inspected. The ceramic shell is mechanically removed, e.g., by blunt force (or other mechanical action), after the metal is hardened.
- the wax tree is placed within a flask, which is then filled with the ceramic slurry.
- the flask, with the hardened ceramic may be placed in a furnace and heated to remove the wax, and to harden the ceramic coating.
- the hardening may be in a separate heat-treating step.
- the ceramic mold is then ready for casting.
- molten metal is also poured into the pour-cup and then passes into the down-sprue and runner system to feed the component pattern(s).
- the ceramic is also mechanically removed after the metal is solidified. Parts cast from these processes should be relatively defect free to meet manufacturing needs.
- Patent documents US 2017/087626 A1 , US 9 901 976 B2 , US 2019/358850 A1 and EP 2 792 771 A1 relate to a lost-wax method of casting a product using inserts disposed inside the mould in order to control the thermal constraints during solidification.
- molten metal may undesirably solidify within the sprue, runners or assembly gating as well as within the component to which the assembly gating is attached before reaching the part pattern chamber. This may, result in casting defects which would cause the need for rework and repair, or would scrap the parts.
- the molten metal may cool unevenly within the part pattern chamber due to a variation of geometries within the part pattern chamber. For example, a relatively large mass of molten metal at thicker portions of a part pattern may result in an excess of heat in the same location compared with a thinner portion of the part pattern. Thus, thicker portions may cool more slowly than thinner portions of the part pattern within the part pattern chamber. The cooling dynamics may result in undesirable residual stress and strain in the final cast part.
- the temperature control elements 100 take the form of thermal sink elements (or chillers) 100A1-100A5 (generally referenced as 100A).
- the thermal sink elements 100A are respectively applied to first portions 210A1, 210A2 (generally referenced as 210A) of a part pattern section 120 of a wax assembly 140 (or wax investment).
- the thermal sink elements 100A are applied to a side surface 125A, also referred to as an outer surface, of the part pattern section 120.
- the part pattern section 120 is three dimensional and thus has front and back surfaces 125B, 125C, identified schematically, and the thermal sink elements 100A may be applied there as well.
- thermal sink elements 100A4, 100A5 are schematically shown for the front and back surfaces 125B, 125C, respectively.
- the first portions 210A are relatively thick portions of the part pattern section 120 compared with, e.g., second portions 220B1, 220B2 (generally referenced as 220B) which may be near the respective first portions 210A.
- the thermal sink elements 100A are configured to provide for thermal control of the casting process by drawing out excess heat from molten material 180 utilized during the casting process. Faster solidification in areas of greater mass will result in more sound cast metal with less micro-porosity and macro-porosity defects. This is especially true if the area of larger mass is contained within regions of small mass where proper metal fill and solidification are not possible.
- the temperature control elements 100 take the form of insulating elements (or thermal barriers) 100B1-100B6 (generally referenced as 100B).
- the insulating elements 100B are respectively applied to a sprue pattern section 190 and gate-land pattern sections 200A1-200A4 (generally referenced as 200A) of a gate pattern section 130 of the wax assembly 140. Insulating sections may be required.
- the insulating elements 100B are configured to provide for thermal control of the casting process by preventing heat from being drawn out of the molten material 180 ( FIGS. 6-7 ) applied during the casting process.
- the thermal sink elements 100A are formed from conductive material such as metal or ceramic (SiC).
- the thermal sink elements 100A may have a higher thermal conductivity than the wax assembly 140 or a ceramic mold 150 (e.g., FIGS. 2-7 ) that is built around the wax assembly 140 as part of the casting process.
- the thermal sink elements 100A is attached directly to the part pattern section 120 of the wax assembly 140, to the ceramic mold 150, or to the gate pattern section 130 in close proximity to the part pattern section 120.
- the thermal sink elements 100A may extract heat relatively quickly from the part pattern chamber 160 ( FIGS. 2-7 ) to provide a cast part 170 that is relatively sound and defect free.
- the insulating elements 100B may be applied in similar fashion in the gate pattern section 130 to slow down the solidification process for fabricating the cast part 170.
- the insulating elements 100B is a ceramic with lower conductivity than the remainder of the ceramic mold 150.
- the insulating elements 100B may be formed of a material such as monolithic ceramics such as alumina, zircon, silica, etc., or a thermal barrier ceramic with controlled thermal conductivity such as yttria stabilized zirconia (YSZ), or a ceramic matrix composite which can control heat retention or dissipation in a controlled manner .
- YSZ yttria stabilized zirconia
- the disclosed process utilizes the temperature control elements 100 in situ in the investment casting and solid mold casting processes to affect a natural solidification rate of the molten material 180 ( FIG. 8 and 9 ).
- the temperature control elements 100 may do this by directing and removing latent heat. This optimizes the solidification the molten material 180 to form a cast part 170 in the part pattern chamber 160. This process may improve product yields and reduce scrap and rework.
- FIG. 2 shows an investment casting mold assembly 165 and includes the wax assembly 140 encased in the ceramic mold 150 as part of an investment casting process.
- FIG. 2 also shows the thermal sink elements 100A encased in the ceramic mold 150 and positioned against the part pattern section 120.
- the figure shows the insulating elements 100B encased in the ceramic mold 150 and located against the sprue pattern section 190.
- FIG. 3 shows a solid-mold casting assembly 165A and includes the wax assembly 140 encased in the ceramic mold 150 as part of a solid-mold casting process.
- FIG. 3 also shows the thermal sink elements 100A encased in the ceramic mold 150 and located against the part pattern section 120.
- the figure also shows the insulating elements 100B encased in the ceramic mold 150 and located against the sprue pattern section 190 and the gate-land pattern sections 200A.
- FIG. 3 further shows the flask 230 for supporting the ceramic mold 150.
- FIG. 4 shows the ceramic mold 150 with the wax assembly 140 removed as part of an investment casting process.
- FIG. 4 also shows the thermal sink elements 100A at the part pattern chamber 160, the insulating elements 100B at the sprue 190A and the gate-lands 200B1-200B5 (generally referenced as 200B) formed by removal of the wax assembly 140.
- FIG. 4 also shows the gate section 130A formed by removal of the wax assembly 140.
- FIG. 5 shows the ceramic mold 150 with the wax assembly 140 removed as part of a solid-mold casting process.
- FIG. 5 also shows the thermal sink elements 100A at the part pattern chamber 160 formed by removal of the wax assembly 140, and the insulating elements 100B at the sprue 190A the gate-lands 200B formed by removal of the wax assembly 140.
- FIG. 5 further shows the gate section 130A formed by removal of the wax assembly 140 and the flask 230 for supporting the ceramic mold 150.
- FIG. 6 shows the ceramic mold 150, including the sprue 190A, the gate section 130A and the part pattern chamber 160, filled with molten material 180 as part of an investment casting process.
- FIG. 6 also shows the thermal sink elements 100A at the part pattern chamber 160 and the insulating elements 100B at the sprue 190A and the gate-lands 200B.
- FIG. 7 shows the ceramic mold 150, including the sprue 190A, the gate section 130A and the part pattern chamber 160, filled with molten material 180 as part of a solid-mold casting process.
- FIG. 7 also shows the thermal sink elements 100A at the part pattern chamber 160 and the insulating elements 100B at the sprue 190A and the gate-lands 200B.
- FIG. 7 further shows the flask 230 for supporting the ceramic mold 150.
- the insulating elements 100B prevent the molten material 180 from cooling and drying, e.g., at the sprue 190A and the gate-lands 200B.
- the thermal sink elements 100A remove excess heat from molten material 180 in the part pattern chamber 160 adjacent to where it is placed. Thus, placing the thermal sink elements 100A next to a thicker portion of the part pattern chamber 160 enable cooling at a similar rate as a thinner portion of the part pattern chamber 160.
- FIG. 8 shows the cast part 170 with the ceramic mold removed as part of either the investment casting process or the solid mold process. Excess metal 170A is around the cast part 170 in locations corresponding to the sprue 190A and gate section 130A (e.g., FIGS. 6-7 ).
- FIG. 9 shows the cast part 170 in the final form, with the excess metal 170A removed.
- FIG. 10 is a flowchart showing a lost-wax method of casting a part, i.e., to provide the cast part 170.
- the method includes attaching the temperature control elements 100 to the wax assembly 140.
- the method includes encasing the wax assembly 140 and the temperature control elements 100 in the ceramic mold 150.
- the method includes removing the wax assembly 140 from the ceramic mold 150.
- the method includes filling the ceramic mold 150 with molten material 180 to form the cast part 170 within the ceramic mold 150.
- the method includes separating the ceramic mold 150 and the cast part 170 from each other.
- the method may further include attaching the thermal sink elements 100A to the part pattern section 120 of the wax assembly 140.
- the method may further include attaching the insulating elements 100B to the sprue pattern section 190 and the gate-land pattern sections 200A of the wax assembly 140.
- the method further includes attaching steel blocks (as the thermal sink elements 100A) to the part pattern section of the wax assembly 140 to draw heat from the molten material 180.
- the method may include positioning the thermal sink elements 100A closer to the first portions 210A of the part pattern section 120 of the wax assembly 140 than the second portions 220A of the part pattern section 120 of the wax assembly 140.
- the first portions 210A are thicker than the second portions 220A.
- the method may include positioning the thermal sink elements 100A about one or more of side, front and back surfaces 125A-125C of the wax assembly 140.
- the method further includes attaching the temperature control elements 100 directly to the part pattern section 120 of the wax assembly 140.
- the thermal sink elements 100A may be formed of metal having a melting temperature that is greater than the molten material 180.
- the thermal sink elements 100A will remain solid and not contaminate the molten material 180.
- the insulating elements 100B are also formed of a material that will not contaminate the molten material 180, and may be, e.g., a ceramic as indicated above.
- the temperature control elements 100 may be attached the wax assembly 140 via, e.g., additional melted wax.
- the method may include forming the ceramic mold 150 about the wax assembly 140 to a first thickness to define a first layer of the ceramic mold 150.
- the method may include, as shown in block 240, attaching the temperature control elements 100 to the first layer of the ceramic mold 150.
- a thin layer of ceramic may separate the temperature control elements 100 from the wax assembly 140. This minimizes a likelihood of cross contamination between the molten material 180 and either of the temperature control elements 100.
- the method may further include forming the ceramic mold 150 about the wax assembly 140 to a second thickness that is greater than the first thickness. This action encases the temperature control elements 100 within the ceramic mold 150. With this configuration, the temperature control elements 100 are securely contained and structurally isolated within the ceramic mold 150.
- the method may further include forming layers of the ceramic mold 150 to build-up the ceramic mold 150 to the second thickness. This action forms the ceramic mold 150 about the wax assembly 140.
- Forming layers of the ceramic mold 150 may include encasing the wax assembly in a ceramic slurry, and drying the ceramic slurry, and repeating.
- the method may further include positioning the wax assembly 140 in a flask 230.
- the method may further include, as shown in block 280, filling the flask 230 with the ceramic slurry. This action forms the ceramic mold 150 about the wax assembly 140.
- the method may include mechanically separating, e.g., with application of blunt force (or other mechanical action, such as the utilization of a hammer or other impact implement), the ceramic mold 150 and the cast part 170 from each other.
- the method may further include thermally removing wax from and firing (e.g., applying fire or other similar heat source to) the ceramic mold 150 to sinter the ceramic and prepare the ceramic mold 150 for casting. Such heat treatment assists in strengthening the ceramic mold 150 so that it may withstand the temperature and the weight of the molten material 180.
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Description
- The embodiments herein relate to casting of materials and more specifically to thermal management in lost wax casting.
- Production of metal parts from lost-wax casting enables replication of parts on small and mass scales. Investment casting may include a wax part pattern of an article to be cast, which may be produced from a die mold. The component wax pattern may be connected with injected wax shapes on a wax assembly, which will typically possesses a pour-cup, down-sprue, wax in-gates, and then the component pattern itself. The wax tree, with the part patterns, is then coated with a ceramic slurry to form a ceramic shell over its surface.
- After ceramic slurry application, the wax assembly may then be withdrawn from the slurry and dried. The steps of coating and drying are repeated until a ceramic shell mold around the wax tree is of a sufficient thickness, which may depend on the weight of the cast assembly. The wax tree, with the ceramic shell, is then placed in a furnace pressurized steam de-waxer vessel removes the wax from the inside of the ceramic mold. The ceramic mold is then placed into a furnace to heat and sinter the ceramic particles to strengthen the mold to enable the receipt of a certain volume of molten metal.
- The hardening may be in a separate thermal processing step. The ceramic mold is then ready for the casting of the part. Molten metal is poured into the pour-cup and passed through the sprue and ingates into the component cavity once defined by the wax assembly. After the metal has solidified, the ceramic shell is removed mechanically to reveal the metal components on the assembly. The cast components are then removed from the assembly, mechanically finished and inspected. The ceramic shell is mechanically removed, e.g., by blunt force (or other mechanical action), after the metal is hardened.
- For Solid mold casting, the wax tree is placed within a flask, which is then filled with the ceramic slurry. The flask, with the hardened ceramic, may be placed in a furnace and heated to remove the wax, and to harden the ceramic coating. The hardening may be in a separate heat-treating step. The ceramic mold is then ready for casting. In this form of casting, molten metal is also poured into the pour-cup and then passes into the down-sprue and runner system to feed the component pattern(s). The ceramic is also mechanically removed after the metal is solidified. Parts cast from these processes should be relatively defect free to meet manufacturing needs.
- Patent documents
US 2017/087626 A1 ,US 9 901 976 B2 US 2019/358850 A1 andEP 2 792 771 A1 relate to a lost-wax method of casting a product using inserts disposed inside the mould in order to control the thermal constraints during solidification. - Disclosed is a lost-wax method of casting a product and a mould assembly as disclosed in appended claims 1-10.
- The present disclosure is illustrated by way of example and not limited in the accompanying figures in which like reference numerals indicate similar elements.
-
FIG. 1 shows a wax assembly with temperature control elements according to an embodiment; -
FIG. 2 shows the wax assembly encased in a ceramic mold as part of an investment casting process according to an embodiment; -
FIG. 3 shows the wax assembly encased in the ceramic mold as part of a solid-mold casting process according to an embodiment; -
FIG. 4 shows the ceramic mold, with the wax assembly removed, as part of an investment casting process according to an embodiment; -
FIG. 5 shows the ceramic mold, with the wax assembly removed, as part of a solid-mold casting process according to an embodiment; -
FIG. 6 shows the ceramic mold, including a sprue, a gate section and a part pattern chamber, filled with molten material as part of an investment casting process according to an embodiment; -
FIG. 7 shows the ceramic mold, including a sprue, a gate section and a part pattern chamber, filled with molten material, as part of a solid-mold casting process according to an embodiment; -
FIG. 8 shows a cast part, with the ceramic mold removed, as part of either the investment casting process or the solid mold process according to an embodiment; -
FIG. 9 shows the cast part in a final form, with excess metal removed according to an embodiment; and -
FIG. 10 is a flowchart showing a lost-wax method of casting a part according to an embodiment. - A detailed description of one or more embodiments of the disclosed apparatus and method are presented herein by way of exemplification and not limitation with reference to the Figures.
- During investment and solid mold type lost-wax casting, molten metal may undesirably solidify within the sprue, runners or assembly gating as well as within the component to which the assembly gating is attached before reaching the part pattern chamber. This may, result in casting defects which would cause the need for rework and repair, or would scrap the parts. In addition, the molten metal may cool unevenly within the part pattern chamber due to a variation of geometries within the part pattern chamber. For example, a relatively large mass of molten metal at thicker portions of a part pattern may result in an excess of heat in the same location compared with a thinner portion of the part pattern. Thus, thicker portions may cool more slowly than thinner portions of the part pattern within the part pattern chamber. The cooling dynamics may result in undesirable residual stress and strain in the final cast part.
- As shown in
FIG. 1 , in view of the above identified concerns with lost wax investment and solid-mold type lost-wax casting, the disclosed embodiments utilizetemperature control elements 100. Thetemperature control elements 100 take the form of thermal sink elements (or chillers) 100A1-100A5 (generally referenced as 100A). Thethermal sink elements 100A are respectively applied to first portions 210A1, 210A2 (generally referenced as 210A) of apart pattern section 120 of a wax assembly 140 (or wax investment). As shown, thethermal sink elements 100A are applied to aside surface 125A, also referred to as an outer surface, of thepart pattern section 120. However, thepart pattern section 120 is three dimensional and thus has front andback surfaces thermal sink elements 100A may be applied there as well. For example, thermal sink elements 100A4, 100A5 are schematically shown for the front andback surfaces - The
first portions 210A are relatively thick portions of thepart pattern section 120 compared with, e.g., second portions 220B1, 220B2 (generally referenced as 220B) which may be near the respectivefirst portions 210A. Thethermal sink elements 100A are configured to provide for thermal control of the casting process by drawing out excess heat frommolten material 180 utilized during the casting process. Faster solidification in areas of greater mass will result in more sound cast metal with less micro-porosity and macro-porosity defects. This is especially true if the area of larger mass is contained within regions of small mass where proper metal fill and solidification are not possible. - Additionally, the
temperature control elements 100 take the form of insulating elements (or thermal barriers) 100B1-100B6 (generally referenced as 100B). Theinsulating elements 100B are respectively applied to asprue pattern section 190 and gate-land pattern sections 200A1-200A4 (generally referenced as 200A) of agate pattern section 130 of thewax assembly 140. Insulating sections may be required. Theinsulating elements 100B are configured to provide for thermal control of the casting process by preventing heat from being drawn out of the molten material 180 (FIGS. 6-7 ) applied during the casting process. - The
thermal sink elements 100A are formed from conductive material such as metal or ceramic (SiC). Thethermal sink elements 100A may have a higher thermal conductivity than thewax assembly 140 or a ceramic mold 150 (e.g.,FIGS. 2-7 ) that is built around thewax assembly 140 as part of the casting process. Thethermal sink elements 100A is attached directly to thepart pattern section 120 of thewax assembly 140, to theceramic mold 150, or to thegate pattern section 130 in close proximity to thepart pattern section 120. Thethermal sink elements 100A may extract heat relatively quickly from the part pattern chamber 160 (FIGS. 2-7 ) to provide acast part 170 that is relatively sound and defect free. - The
insulating elements 100B may be applied in similar fashion in thegate pattern section 130 to slow down the solidification process for fabricating thecast part 170. The insulatingelements 100B is a ceramic with lower conductivity than the remainder of theceramic mold 150. The insulatingelements 100B may be formed of a material such as monolithic ceramics such as alumina, zircon, silica, etc., or a thermal barrier ceramic with controlled thermal conductivity such as yttria stabilized zirconia (YSZ), or a ceramic matrix composite which can control heat retention or dissipation in a controlled manner . - Thus, the disclosed process utilizes the
temperature control elements 100 in situ in the investment casting and solid mold casting processes to affect a natural solidification rate of the molten material 180 (FIG. 8 and 9 ). Thetemperature control elements 100 may do this by directing and removing latent heat. This optimizes the solidification themolten material 180 to form acast part 170 in thepart pattern chamber 160. This process may improve product yields and reduce scrap and rework. -
FIG. 2 shows an investmentcasting mold assembly 165 and includes thewax assembly 140 encased in theceramic mold 150 as part of an investment casting process.FIG. 2 also shows thethermal sink elements 100A encased in theceramic mold 150 and positioned against thepart pattern section 120. The figure shows the insulatingelements 100B encased in theceramic mold 150 and located against thesprue pattern section 190. -
FIG. 3 shows a solid-mold casting assembly 165A and includes thewax assembly 140 encased in theceramic mold 150 as part of a solid-mold casting process.FIG. 3 also shows thethermal sink elements 100A encased in theceramic mold 150 and located against thepart pattern section 120. The figure also shows the insulatingelements 100B encased in theceramic mold 150 and located against thesprue pattern section 190 and the gate-land pattern sections 200A.FIG. 3 further shows theflask 230 for supporting theceramic mold 150. -
FIG. 4 shows theceramic mold 150 with thewax assembly 140 removed as part of an investment casting process.FIG. 4 also shows thethermal sink elements 100A at thepart pattern chamber 160, the insulatingelements 100B at thesprue 190A and the gate-lands 200B1-200B5 (generally referenced as 200B) formed by removal of thewax assembly 140.FIG. 4 also shows thegate section 130A formed by removal of thewax assembly 140. -
FIG. 5 shows theceramic mold 150 with thewax assembly 140 removed as part of a solid-mold casting process.FIG. 5 also shows thethermal sink elements 100A at thepart pattern chamber 160 formed by removal of thewax assembly 140, and the insulatingelements 100B at thesprue 190A the gate-lands 200B formed by removal of thewax assembly 140.FIG. 5 further shows thegate section 130A formed by removal of thewax assembly 140 and theflask 230 for supporting theceramic mold 150. -
FIG. 6 shows theceramic mold 150, including thesprue 190A, thegate section 130A and thepart pattern chamber 160, filled withmolten material 180 as part of an investment casting process.FIG. 6 also shows thethermal sink elements 100A at thepart pattern chamber 160 and the insulatingelements 100B at thesprue 190A and the gate-lands 200B. -
FIG. 7 shows theceramic mold 150, including thesprue 190A, thegate section 130A and thepart pattern chamber 160, filled withmolten material 180 as part of a solid-mold casting process.FIG. 7 also shows thethermal sink elements 100A at thepart pattern chamber 160 and the insulatingelements 100B at thesprue 190A and the gate-lands 200B.FIG. 7 further shows theflask 230 for supporting theceramic mold 150. - The insulating
elements 100B prevent themolten material 180 from cooling and drying, e.g., at thesprue 190A and the gate-lands 200B. Thethermal sink elements 100A remove excess heat frommolten material 180 in thepart pattern chamber 160 adjacent to where it is placed. Thus, placing thethermal sink elements 100A next to a thicker portion of thepart pattern chamber 160 enable cooling at a similar rate as a thinner portion of thepart pattern chamber 160. -
FIG. 8 shows thecast part 170 with the ceramic mold removed as part of either the investment casting process or the solid mold process.Excess metal 170A is around thecast part 170 in locations corresponding to thesprue 190A andgate section 130A (e.g.,FIGS. 6-7 ).FIG. 9 shows thecast part 170 in the final form, with theexcess metal 170A removed. -
FIG. 10 is a flowchart showing a lost-wax method of casting a part, i.e., to provide thecast part 170. As shown inblock 100, the method includes attaching thetemperature control elements 100 to thewax assembly 140. As shown inblock 110, the method includes encasing thewax assembly 140 and thetemperature control elements 100 in theceramic mold 150. As shown inblock 120, the method includes removing thewax assembly 140 from theceramic mold 150. As shown inblock 130 inFIG. 10 , the method includes filling theceramic mold 150 withmolten material 180 to form thecast part 170 within theceramic mold 150. As shown inblock 140 the method includes separating theceramic mold 150 and thecast part 170 from each other. - Additionally, as shown in
block 150, the method may further include attaching thethermal sink elements 100A to thepart pattern section 120 of thewax assembly 140. As shown inblock 160, the method may further include attaching the insulatingelements 100B to thesprue pattern section 190 and the gate-land pattern sections 200A of thewax assembly 140. - As shown in
block 170, the method further includes attaching steel blocks (as thethermal sink elements 100A) to the part pattern section of thewax assembly 140 to draw heat from themolten material 180. As shown inblock 180, the method may include positioning thethermal sink elements 100A closer to thefirst portions 210A of thepart pattern section 120 of thewax assembly 140 than thesecond portions 220A of thepart pattern section 120 of thewax assembly 140. As indicated, thefirst portions 210A are thicker than thesecond portions 220A. As shown inblock 200, the method may include positioning thethermal sink elements 100A about one or more of side, front and back surfaces 125A-125C of thewax assembly 140. - As shown in
block 220, the method further includes attaching thetemperature control elements 100 directly to thepart pattern section 120 of thewax assembly 140. In such embodiment thethermal sink elements 100A may be formed of metal having a melting temperature that is greater than themolten material 180. Thus, whenmolten material 180 contacts thethermal sink elements 100A, thethermal sink elements 100A will remain solid and not contaminate themolten material 180. Similarly, the insulatingelements 100B are also formed of a material that will not contaminate themolten material 180, and may be, e.g., a ceramic as indicated above. Thetemperature control elements 100 may be attached thewax assembly 140 via, e.g., additional melted wax. - In one embodiment, as shown in
block 230, the method may include forming theceramic mold 150 about thewax assembly 140 to a first thickness to define a first layer of theceramic mold 150. The method may include, as shown inblock 240, attaching thetemperature control elements 100 to the first layer of theceramic mold 150. In this embodiment, a thin layer of ceramic may separate thetemperature control elements 100 from thewax assembly 140. This minimizes a likelihood of cross contamination between themolten material 180 and either of thetemperature control elements 100. - As shown in
block 250, the method may further include forming theceramic mold 150 about thewax assembly 140 to a second thickness that is greater than the first thickness. This action encases thetemperature control elements 100 within theceramic mold 150. With this configuration, thetemperature control elements 100 are securely contained and structurally isolated within theceramic mold 150. - In one unclaimed embodiment, as shown in
block 260, the method may further include forming layers of theceramic mold 150 to build-up theceramic mold 150 to the second thickness. This action forms theceramic mold 150 about thewax assembly 140. Forming layers of theceramic mold 150 may include encasing the wax assembly in a ceramic slurry, and drying the ceramic slurry, and repeating. In one embodiment, as shown inblock 270, the method may further include positioning thewax assembly 140 in aflask 230. The method may further include, as shown inblock 280, filling theflask 230 with the ceramic slurry. This action forms theceramic mold 150 about thewax assembly 140. - As shown in
block 290, the method may include mechanically separating, e.g., with application of blunt force (or other mechanical action, such as the utilization of a hammer or other impact implement), theceramic mold 150 and thecast part 170 from each other. As shown inblock 300, the method may further include thermally removing wax from and firing (e.g., applying fire or other similar heat source to) theceramic mold 150 to sinter the ceramic and prepare theceramic mold 150 for casting. Such heat treatment assists in strengthening theceramic mold 150 so that it may withstand the temperature and the weight of themolten material 180. - The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the present disclosure. As used herein, the singular forms "a", "an" and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms "comprises" and/or "comprising," when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, element components, and/or groups thereof.
- Those of skill in the art will appreciate that various example embodiments are shown and described herein, each having certain features in the particular embodiments, but the present disclosure is not thus limited. Rather, while various embodiments of the present disclosure have been described, it is to be understood that aspects of the present disclosure may include only some of the described embodiments. Accordingly, the present disclosure is not to be seen as limited by the foregoing description, but is only limited by the scope of the appended claims.
Claims (10)
- A lost-wax method of casting a product, comprising:attaching (100) temperature control elements (100) to a wax assembly (140), wherein the temperature control elements (100) include thermal sink elements (100A1-100A5) that are steel blocks of different sizes and insulating elements (100B) that are ceramic with a lower conductivity than the remainder of the ceramic mold, andthe method includes:attaching the thermal sink elements (100A1-100A5) to a part pattern section (120) of the wax assembly (140), including side, front and back surfaces (125A, 125B, 125C) of the wax assembly (140);positioning the thermal sink elements (100A1-100A5) closer to first portions (210A) of the part pattern section (120) of the wax assembly (140) than second portions (220A) of the part pattern section (120) of the wax assembly (140), wherein the first portions (210A) are thicker than the second portions (220A);attaching the insulating elements (100B) to a sprue pattern section (190) and gate-land pattern sections (200A) of the wax assembly (140);encasing (110) the wax assembly (140) and the temperature control elements (100) in a ceramic mold (150);removing (120) the wax assembly (140) from the ceramic mold;filling (130) the ceramic mold (150) with molten material to form a cast part within the ceramic mold (150); andseparating (140) the ceramic mold (150) and the cast part from each other.
- The method of claim 1, wherein the method includes:
attaching the steel blocks to the part pattern section to draw heat from the molten material. - The method of any preceding claim, comprising:
attaching the temperature control elements directly to the wax assembly. - The method of any preceding claim, comprising:forming the ceramic mold about the wax assembly to a first thickness to define a first layer of the ceramic mold; andattaching the temperature control elements to the first layer of the ceramic mold.
- The method of claim 4, comprising
forming the ceramic mold about the wax assembly to a second thickness that is greater than the first thickness to encase the temperature control elements within the ceramic mold. - The method of claim 5, further comprising
forming the ceramic mold about the wax assembly to the second thickness by repeatedly: drenching the wax assembly in a ceramic slurry; and drying the ceramic slurry. - The method of claim 5 or 6 further comprising
forming the ceramic mold about the wax assembly to the second thickness by:positioning the wax assembly in a flask; andfilling the flask with a ceramic slurry. - The method of any preceding claim, further comprisingseparating the ceramic mold and the cast part from each other by mechanical action, or includingthermally removing wax from and firing the ceramic mold to sinter the ceramic and prepare the ceramic mold for casting.
- A mold assembly, comprising:a wax assembly (140) including:a part pattern section (120);a gate pattern section (130) connected around an outer surface the part pattern section (120) and defining a sprue pattern section (190) and gate-land pattern sections (200A); andtemperature control elements (100) connected to the wax assembly (140),wherein the temperature control elements (100) include thermal sink elements (100A1-100A5) that are steel blocks of different sizes and insulatingelements (100B) that are ceramic with a lower conductivity than the remainder of the ceramic mold,the thermal sink elements (100A1-100A5) are attached to a part pattern section (120) of the wax assembly (140), including side, front and back surfaces (125A, 125B, 125C) of the wax assembly (140);the thermal sink elements (100A1-100A5) are positioned closer to first portions (210A) of the part pattern section (120) of the wax assembly (140) than second portions (220A) of the part pattern section (120) of the wax assembly (140), wherein the first portions (210A) are thicker than the second portions (220A),the insulating elements (100B) are attached to a sprue pattern section (190) and gate-land pattern sections (200A) of the wax assembly (140), andwherein a ceramic mold (150) encases the wax assembly (140) and the temperature control elements (100).
- The mold assembly of claim 9, wherein the temperature control elements are disposed between layers of ceramic in the ceramic mold.
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US202063022179P | 2020-05-08 | 2020-05-08 |
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US10688555B2 (en) * | 2013-01-18 | 2020-06-23 | Nemak Wernigerode Gmbh | Method and casting mould for the manufacture of cast parts, in particular cylinder blocks and cylinder heads, with a functional feeder connection |
US9415438B2 (en) * | 2013-04-19 | 2016-08-16 | United Technologies Corporation | Method for forming single crystal parts using additive manufacturing and remelt |
JP6559495B2 (en) * | 2015-07-29 | 2019-08-14 | 株式会社キャステム | Manufacturing method of casting using lost wax method |
US20170087626A1 (en) * | 2015-09-30 | 2017-03-30 | Crucible Intellectual Property, Llc | Investment-diecasting mold |
US10391670B2 (en) * | 2017-06-28 | 2019-08-27 | General Electric Company | Additively manufactured integrated casting core structure with ceramic shell |
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