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Investment casting utilizing flexible wax pattern tool for supporting a ceramic core along its length during wax injection

a technology of flexible wax pattern and ceramic core, which is applied in the field of investment casting, can solve the problems of not being able to survive in the surface of wax during subsequent handling, and achieve the effect of reducing the incidence of damage or movement of the cor

Inactive Publication Date: 2013-12-19
MIKRO SYSYTEMS INC +1
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

The present invention is a new method for investment casting that uses a flexible tool to protect a ceramic core during the wax injection step. This allows for higher pressures while reducing damage or movement of the core. The method also involves using a flexible wax pattern mold that has a flexible insert for easier removal of the tool from the cast wax pattern. The flexible insert is made from a low-cost, low-hardness material, such as aluminum or mild steel, which is cast from a master tool. The overall process improves the quality and efficiency of the investment casting process.

Problems solved by technology

Some desired surface topographies are so fine that they may not survive in the surface of the wax during subsequent handling and ceramic shell forming steps.

Method used

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  • Investment casting utilizing flexible wax pattern tool for supporting a ceramic core along its length during wax injection
  • Investment casting utilizing flexible wax pattern tool for supporting a ceramic core along its length during wax injection
  • Investment casting utilizing flexible wax pattern tool for supporting a ceramic core along its length during wax injection

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Embodiment Construction

[0035]As part of an investment casting process such as may be used for casting a gas turbine blade or other component with complex internal cooling passages, a ceramic core is first produced which will define the shape of the internal cooling passages. FIG. 1 is an illustration of one such ceramic core 10 which may be formed by any known process.

[0036]Once the ceramic core is produced, the next step in the investment casting process is to use the core as part of wax pattern tool for casting wax around the core to define the eventual outer surface shape of the cast blade or other cast part. Prior art wax pattern tooling design is especially complicated and expensive when multiple pull planes are required for removal of the tooling from the wax pattern or cast part due to the geometry of the part. The present invention provides a novel approach to wax pattern tooling which reduces the tool manufacturing time and cost to a small fraction of that required for traditional wax pattern too...

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Abstract

An investment casting process wherein the wax pattern tool (42) is flexible to provide compliant support for an enclosed ceramic core (10) and to facilitate removal of the tool from the cast wax pattern (52) even when the cast shape would otherwise require multiple pull planes. Positioning pins (106) may extend from the flexible tool to make compliant contact against the core during the wax injection step. The pins may cooperate with a pedestal (128) formed on the core to support the core along multiple axes during wax injection, thereby allowing a higher wax injection pressure without damage to the core.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS[0001]This application is a continuation-in-part of co-pending application Ser. No. 12 / 961,740 filed 7 Dec. 2010 (attorney docket 2010P13199US), which in turn claimed benefit of the 8 Dec. 2009 filing date of U.S. provisional application No. 61 / 267,519 (attorney docket 2009P22785US).FIELD OF THE INVENTION[0002]This invention relates generally to the field of investment casting, and more particularly, to using a flexible tool or mold to form a wax pattern as part of an investment casting process.BACKGROUND OF THE INVENTION[0003]Investment casting is one of the oldest known metal-forming processes, dating back thousands of years to when it was first used to produce detailed artwork from metals such as copper, bronze and gold. Industrial investment castings became more common in the 1940's when World War II increased the demand for precisely dimensioned parts formed of specialized metal alloys. Today, investment casting is commonly used in the aer...

Claims

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Application Information

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Patent Type & Authority Applications(United States)
IPC IPC(8): B22C7/02
CPCB22C7/02B22C9/02B22C9/04B22C9/103B22C9/24B22C21/14
Inventor MERRILL, GARY B.JAMES, ALLISTER WILLIAMSSHEEHAN, KEVIN C.HENEVELD, BENJAMIN E.FRASER, IAIN ALASDAIR
Owner MIKRO SYSYTEMS INC
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