Variable Diameter Investment Casting Mold For Casting of Reticulated Metal Foams

A method to manufacture reticulated metal foam via a dual investment solid mold, includes pre-investing a precursor with a diluted pre-investment ceramic plaster to encapsulate the precursor; and investing the encapsulated precursor with a ceramic plaster within an mold of a varied cross-section. A varied cross-section mold includes a mold thickness adjacent to an outer periphery of a pattern at a top of the varied cross-section mold is between 200-500% a thickness between the outer periphery of the pattern at a base of the varied cross-section mold. A varied cross-section mold includes a trapezoidal prism shape with a pour cone in a top, the top larger than the base. 1. A method to manufacture reticulated metal foam via a dual investment solid mold , comprising:pre-investing a precursor with a pre-investment ceramic plaster to encapsulate the precursor.2. The method as recited in claim 1 , further comprising investing the encapsulated precursor with a ceramic plaster within a varied cross-section mold claim 1 , the varied cross-section mold is of a trapezoidal prism shape.3. The method as recited in claim 1 , wherein the varied cross-section mold forms a mold thickness between an outer periphery of the encapsulated precursor at a top of the encapsulated precursor is between 200-500% a thickness between the outer periphery of the encapsulated precursor at a base of the encapsulated precursor.4. The method as recited in claim 1 , wherein the varied cross-section mold forms a ratio between a top to a base thereof that is about 3:1.5. The method as recited in claim 4 , wherein the varied cross-section mold is of a trapezoidal prism shape.6. The method as recited in claim 1 , wherein the precursor is a reticulated foam.7. The method as recited in claim 1 , wherein the precursor is a polyurethane foam.8. The method as recited in claim 1 , wherein the precursor is completely encapsulated with the pre-investment ceramic plaster.9. The method as recited in claim 1 , further ...

DUAL INVESTMENT SHELLED SOLID MOLD CASTING OF RETICULATED METAL FOAMS

A method to manufacture reticulated metal foam via a dual investment, includes pre-investment of a precursor with a diluted pre-investment ceramic plaster then applying an outer mold to the encapsulated precursor as a shell-mold. 1. A method to manufacture reticulated metal foam via a dual investment , comprising:pre-investing a precursor with a diluted pre-investment ceramic plaster to encapsulate the precursor; andapplying an outer mold to the encapsulated precursor as a shell-mold.2. The method as recited in claim 1 , wherein the precursor is a reticulated foam.3. The method as recited in claim 1 , wherein the precursor is a polyurethane foam.4. The method as recited in claim 1 , wherein the precursor is completely encapsulated with the diluted pre-investment ceramic plaster.5. The method as recited in claim 1 , further comprising claim 1 , coating the precursor to increase ligament thickness.6. The method as recited in claim 1 , further comprising claim 1 , coating the precursor in a molten wax to increase ligament thickness to provide an about 90% air to 10% precursor ratio.7. The method as recited in claim 1 , further comprising claim 1 , coating the precursor in a molten wax to increase ligament thickness to provide an about 90% air to 10% precursor ratio.8. The method as recited in claim 1 , wherein the diluted pre-investment ceramic plaster is about 55:100 water-to-powder ratio.9. The method as recited in claim 1 , further comprising applying the outer mold by applying alternating layers of slurry and stucco to form the shell-mold.10. A method to manufacture reticulated metal foam via a dual investment claim 1 , comprising:coating a precursor in a molten wax to increase ligament thickness;pre-investing the waxed precursor with a diluted pre-investment ceramic plaster to encapsulate the precursor; andapplying an outer mold to the encapsulated precursor as a shell-mold.11. The method as recited in claim 10 , wherein the precursor is a reticulated foam.12. The ...

CASTING WITH REUSABLE PRECISION, MOTION-CONTROLLED, WITHDRAWABLE CORES

A method of manufacturing includes providing a casting assembly, providing a material having solid, transition, and liquid phases, heating the material to form the liquid phase, supplying the material to the casting assembly, cooling the material, monitoring the solidification of the material from the liquid phase through the transition phase, and moving one of the casting mold or the reusable core in a first direction relative to the other when a substantial portion of the reusable core contacts the transition phase. The casting assembly comprises a casting mold and a reusable core inserted within the casting mold. 1. A method of manufacturing includes: a casting mold; and', 'a reusable core inserted within the casting mold;, 'providing a casting assembly comprisingproviding a material that has a solidus temperature and a liquidus temperature, wherein the material has a solid phase at a temperature less than or equal to the solidus temperature, a transition phase at a temperature between the solidus and liquidus temperatures, and a liquid phase at a temperature greater than or equal to the liquidus temperature;heating the material to form the liquid phase;supplying the material to the casting assembly;cooling the material;monitoring a solidification of the material from the liquid phase through the transition phase; andmoving at least one of the casting mold and the reusable core in a first direction relative to the other when a substantial portion of the reusable core contacts the material in the transition phase.2. The method of claim 1 , wherein the reusable core moves relative to the casting mold.3. The method of and further including:removing the reusable core from the casting mold, wherein a viscosity of the material surrounding the reusable core at a time immediately preceding the removal of the core is sufficient to form one or more hollow cavities within the material.4. The method of and further including:heating the casting assembly during the removal of ...

Chill Plate for Equiax Casting Solidification Control For Solid Mold Casting of Reticulated Metal Foams

A method to manufacture reticulated metal foam via a dual investment solid mold includes pouring molten metal material into a mold while the mold is located on a chill plate. A method to manufacture reticulated metal foam includes pouring molten metal material into a mold while the mold is located on a chill plate, the chill plate configured to apply an externally driven temperature gradient in the mold so that solidification progresses from the chilled end to the non-chilled end 1. A method to manufacture reticulated metal foam , comprising:pouring molten metal material into a mold while the mold is located on a chill plate operable to provide chilling of an extent that a casting formed by the mold remains equiaxial with crystallization nucleating from all surfaces.2. The method as recited in claim 1 , further comprising:pre-investing a precursor with a diluted pre-investment ceramic plaster to encapsulate the precursor; andinvesting the encapsulated precursor with a ceramic plaster to form the mold.3. The method as recited in claim 2 , wherein the precursor is a reticulated foam structure.4. The method as recited in claim 2 , wherein the precursor is a polyurethane reticulated foam structure.5. The method as recited in claim 2 , wherein the precursor is completely encapsulated with the diluted pre-investment ceramic plaster.6. The method as recited in claim 2 , further comprising claim 2 , coating the precursor in a molten wax to increase ligament thickness.7. The method as recited in claim 2 , further comprising claim 2 , coating the precursor in a molten wax to increase ligament thickness to provide an about 90% air to 10% precursor ratio.8. The method as recited in claim 2 , wherein the ceramic plaster is more rigid than the diluted pre-investment ceramic plaster.9. The method as recited in claim 2 , wherein the diluted pre-investment ceramic plaster is about 55:100 water to powder ratio.10. The method as recited in claim 2 , wherein the ceramic plaster is ...

Method for Casting Shell Dewaxing

In a method for removing a carbon-containing pattern material from a casting shell, a first step evaporates and pyrolizes the pattern material to leave carbon and a second step oxidizes the carbon. 1. A method for removing a carbon-containing pattern material from a casting shell , the method comprising:a first heating; anda second heating after the first heating, wherein the first heating has a lower minimum pressure than the second heating.2. The method of wherein:the first heating is at a minimum pressure of less than 1.3 Pa.3. The method of wherein:the first heating is at a lower median oxygen partial pressure than a median oxygen partial pressure of the second heating.4. The method of wherein:the first heating peak temperature is at least 816° C.5. The method of wherein:the pattern material consists essentially of wax.6. The method of wherein:the first heating peak temperature is 816° C. to 1093° C.; andthe second heating peak temperature 649° C. to 982° C.7. The method of wherein:the first heating peak is in a first furnace; andthe second heating is in a second furnace, different from the first furnace.8. The method of wherein:the shell contains a casting core.9. The method of wherein:the casting core is a ceramic casting core.10. The method of used to manufacture a gas turbine engine component.11. A casting method including the method of and further comprising:molding the pattern material over a casting core to form a pattern;forming the shell over the pattern;{'claim-ref': {'@idref': 'CLM-00001', 'claim 1'}, 'after the removing of , casting a metallic material in the shell around the casting core; and'}destructively removing the shell and casting core to leave a cast part.12. The method of wherein the cast part consists essentially of a nickel-based superalloy.13. A method for removing a carbon-containing pattern material from a casting shell claim 11 , the method comprising:a first step for evaporating and pyrolizing the pattern material to leave carbon; ...

Arcuate Seed Casting Method

A casting method includes: forming a seed, the seed having a first end and a second end, the forming including bending a seed precursor; placing the seed second end in contact or spaced facing relation with a chill plate; contacting the first end with molten material; and cooling and solidifying the molten material so that a crystalline structure of the seed propagates into the solidifying material. The forming further included reducing a thickness of the seed proximate the first end relative to a thickness of the seed proximate the second end.

APPARATUS AND METHOD FOR INVESTMENT CASTING CORE MANUFACTURE

A method of producing an investment casting ceramic core is provided that includes: providing a core body consisting of a leachable material; surrounding the core body with a mold composition within a vessel, which mold composition is configured to solidify; leaching the core body from the mold composition subsequent to the mold composition solidifying, thereby leaving an internal cavity within the solidified mold composition; depositing a ceramic composition within the internal cavity of the solidified mold composition; sintering the ceramic composition to a solid ceramic core; and removing the solid ceramic core from the mold composition. 1. A method of producing an investment casting ceramic core , comprising:providing a core body consisting of a leachable material;surrounding the core body with a mold composition within a vessel, which mold composition is configured to solidify;leaching the core body from the mold composition subsequent to the mold composition solidifying, thereby leaving an internal cavity within the solidified mold composition;depositing a ceramic composition within the internal cavity of the solidified mold composition;sintering the ceramic composition to a solid ceramic core; andremoving the solid ceramic core from the mold composition.2. The method of claim 1 , wherein the mold composition transforms from the solidified mold composition to a non-solid form during the sintering.3. The method of claim 2 , wherein the mold composition transforms from the solidified mold composition to a loose particulate form during the sintering.4. The method of claim 2 , wherein the mold composition includes one or more body constituents and one or more solidifying constituents.5. The method of claim 4 , wherein the one or more body constituents include at least one refractory material in particulate form.6. The method of claim 5 , wherein the one or more body constituents include one or more of alumina claim 5 , crystalline silica claim 5 , or magnesia ...

Arcuate Seed Casting Method

A casting method includes forming a seed. The seed has a first end and a second end and an inner diameter (ID) surface and an outer diameter (OD) surface. The seed second end is placed in contact or spaced facing relation with a chill plate. The first end is contacted with molten material. The molten material is cooled and solidified so that a crystalline structure of the seed propagates into the solidifying material. At least a portion of the seed contacted with the molten material has a solidus higher than a solidus of at least an initial pour portion of the molten material.

Arcuate Seed Casting Method

A casting method includes: forming a seed, the seed having a first end and a second end, the forming including bending a seed precursor; placing the seed second end in contact or spaced facing relation with a chill plate; contacting the first end with molten material; and cooling and solidifying the molten material so that a crystalline structure of the seed propagates into the solidifying material. The forming further included reducing a thickness of the seed proximate the first end relative to a thickness of the seed proximate the second end. 2. The method of wherein:the seed and the molten material are nickel-based superalloys.3. The method of wherein:the solidus of the seed is no more than 25° C. higher, if at all, than the solidus of an initial pour portion of the molten material.4. The method of wherein:the seed and the molten material are nickel-based superalloys.5. The method of wherein:the reducing comprises electrical discharge machining (EDM).6. The method of wherein:the reducing is before the bending.7. The method of wherein:the reducing is after the bending.8. The method of wherein:the reducing is along an inner diameter face and an outer diameter face of the seed.9. The method of wherein:the reducing is at a plurality of locations circumferentially spaced in the ultimate bent seed.10. The method of wherein:the reducing creates a through cut at each of the locations, optionally open to the first end of the seed.11. The method of wherein:the molten material solidifies in an annular form.13. The casting method of comprising:said reducing the thickness of the seed precursor at the plurality of spaced locations.14. The method of wherein:the reduced thickness facilitates the bending.15. The method of wherein at least one of:the reduced thickness is along a full height of the seed between the first end and the second end;the reducing of the thickness is at nineteen or more locations; andthe bending at least partially closes grooves at the locations.16. The ...

Arcuate Seed Casting Method

A casting method includes forming a seed. The seed has a first end and a second end. The forming includes bending a seed precursor. The seed second end is placed in contact or spaced facing relation a chill plate. The first end is contacted with molten material. The molten material is cooled and solidifies so that a crystalline structure of the seed propagates into the solidifying material. The forming further includes inserting the bent seed precursor into a sleeve leaving the bent seed precursor protruding from a first end of the sleeve

Systems, formulations, and methods for removal of ceramic cores from turbine blades after casting

A solution is provided and includes a strong base, a corrosion inhibitor, wherein the strong base is an alkali metal hydroxide, wherein the corrosion inhibitor is at least one of an organic acid having a-COOH functional group or an alkali metal salt of one of an organic acid having a-COOH functional group.

Systems, formulations, and methods for removal of ceramic cores from turbine blades after casting

A solution is provided comprising a strong base, a corrosion inhibitor, wherein the strong base is an alkali metal hydroxide, wherein the corrosion inhibitor is at least one of an organic acid having a-COOH functional group or an alkali metal salt one of an organic acid having a-COOH functional groups.

METHOD FOR MAGNETIC FLUX COMPENSATION IN A DIRECTIONAL SOLIDIFICATION FURNACE UTILIZING AN ACTUATED SECONDARY COIL

A process for directional solidification of a cast part comprises energizing a primary inductive coil coupled to a chamber having a mold containing a material; generating an electromagnetic field with the primary inductive coil within the chamber, wherein said electromagnetic field is partially attenuated by a susceptor coupled to said chamber between said primary inductive coil and said mold; determining a magnetic flux profile of the electromagnetic field after it passes through the susceptor; sensing a component of the magnetic flux in the interior of the susceptor proximate the mold; positioning a mobile secondary compensation coil within the chamber; generating a control field from a secondary compensation coil, wherein said control field controls said magnetic flux; and casting the material within the mold. 1. A process for directional solidification of a cast part comprising:energizing a primary inductive coil coupled to a chamber having a mold containing a material;generating an electromagnetic field with the primary inductive coil within the chamber, wherein said electromagnetic field is partially attenuated by a susceptor coupled to said chamber between said primary inductive coil and said mold;determining a magnetic flux profile of the electromagnetic field;sensing a component of the magnetic flux proximate the mold within the chamber;positioning a mobile secondary compensation coil within the chamber:generating a control field from said mobile secondary compensation coil, wherein said control field controls said magnetic flux; andcasting the material within the mold.2. The process according to claim 1 , wherein said component of magnetic flux comprises a portion of the total electromagnetic field passing through said mold that is not attenuated by the susceptor.3. The process according to claim 2 , wherein said control field is increased or decreased to control a stirring in the material to produce a predetermined microstructure.4. The process according ...

Method for magnetic flux compensation in a directional solidification furnace utilizing a stationary secondary coil

A process for directional solidification of a cast part comprises energizing a primary inductive coil coupled to a chamber having a mold containing a material; energizing a primary inductive coil within the chamber to heat the mold via radiation from a susceptor, wherein the resultant electromagnetic field partially leaks through the susceptor coupled to the chamber between the primary inductive coil and the mold; determining a magnetic flux profile of the electromagnetic field; sensing a magnetic flux leakage past the susceptor within the chamber; generating a control field from a secondary compensation coil coupled to the chamber, wherein the control field controls the magnetic flux experienced by the cast part; and casting the material within the mold under the controlled degree of flux leakage.

MULTI-LAYER SUSCEPTOR DESIGN FOR MAGNETIC FLUX SHIELDING IN DIRECTIONAL SOLIDIFICATION FURNACES

An induction furnace assembly comprising a chamber having a mold; a primary inductive coil coupled to the chamber; a layered susceptor comprising at least two layers of magnetic field attenuating material surrounding the chamber between the primary inductive coil and the mold to nullify the electromagnetic field in the hot zone of the furnace chamber. 1. A process for directional solidification of a cast part comprising:energizing a primary induction coil coupled to a chamber having a mold containing a casting material;generating an electromagnetic field with the primary induction coil within the chamber, a susceptor coupled to said chamber between said primary induction coil and said mold;transducing at least a portion of said electromagnetic field into heat energy used to heat said mold;attenuating at least a portion of said electromagnetic field with said susceptor, wherein said susceptor comprises at least two layers of electromagnetic shield material; andcasting the material within the mold.2. The process according to claim 1 , wherein said at least two layers comprise a layered susceptor material system.3. The process according to claim 2 , wherein said susceptor comprises a constant thickness for each of said at least two layers.4. The process according to claim 2 , wherein said at least two layers of electromagnetic shield material attenuate the primary induction coil electromagnetic field away from said mold.5. The process according to claim 1 , wherein said susceptor comprises a first layer and a second layer enclosing an interior layer; and said first layer and said second layer are configured for protecting the interior layer from material degradation.6. The process according to claim 5 , further comprising:selecting said electromagnetic field shield material of each of said first layer, second layer and said interior layer responsive to a capacity as an electromagnetic shield for attenuating a total electromagnetic field emitted by said primary ...

SEPARATE VESSEL METAL SHIELDING METHOD FOR MAGNETIC FLUX IN DIRECTIONAL SOLIDIFICATION FURNACE

An induction furnace assembly comprising a chamber having a mold; a primary inductive coil coupled to the chamber; a susceptor surrounding the chamber between the primary inductive coil and the mold; and a shield material contained in a reservoir coupled to or proximate the mold between the susceptor and the mold; the shield material configured to attenuate a portion of an electromagnetic flux generated by the primary induction coil that is not attenuated by the susceptor. 1. A process for directional solidification of a cast part comprising:energizing a primary induction coil within a chamber having a mold containing a material;generating an electromagnetic field with the primary induction coil within the chamber, wherein said electromagnetic field partially leaks through a susceptor coupled to said chamber between said primary induction coil and said mold;controlling a component of a magnetic flux leakage with a shield material coupled to the mold; andcasting the material within the mold.2. The process according to claim 1 ,wherein said component of said magnetic flux leakage comprises a portion of a total electromagnetic field passing through said mold that is not attenuated by the susceptor.3. The process according to claim 2 , wherein said susceptor comprises a constant thickness.4. The process according to claim 2 , wherein the shield material attenuates a portion of the magnetic flux leakage generated by the primary induction coil that is not attenuated by the susceptor.5. The process according to claim 1 , further comprising:a reservoir coupled to said mold, said reservoir configured to contain said shield material.6. The process according to claim 5 , wherein said reservoir is proximate said mold.7. The process according to claim 1 , wherein said reservoir is integral with said mold.8. An induction furnace assembly comprising:a chamber having a mold;a primary induction coil coupled to said chamber;a susceptor surrounding said chamber between said primary ...

Arcuate Seed Casting Method

A casting method includes forming a seed. The seed has a first end and a second end and an inner diameter (ID) surface and an outer diameter (OD) surface. The seed second end is placed in contact or spaced facing relation with a chill plate. The first end is contacted with molten material. The molten material is cooled and solidified so that a crystalline structure of the seed propagates into the solidifying material. At least a portion of the seed contacted with the molten material has a solidus higher than a solidus of at least an initial pour portion of the molten material.

Variable Diameter Investment Casting Mold For Casting of Reticulated Metal Foams

A method to manufacture reticulated metal foam via a dual investment solid mold, includes pre-investing a precursor with a diluted pre-investment ceramic plaster to encapsulate the precursor; and investing the encapsulated precursor with a ceramic plaster within an mold of a varied cross-section. A varied cross-section mold includes a mold thickness adjacent to an outer periphery of a pattern at a top of the varied cross-section mold is between 200-500% a thickness between the outer periphery of the pattern at a base of the varied cross-section mold. A varied cross-section mold includes a trapezoidal prism shape with a pour cone in a top, the top larger than the base. 112-. (canceled)13. A varied cross-section mold , comprising:a mold thickness adjacent to an outer periphery of a pattern at a top of the varied cross-section mold is between 200-500% a thickness between the outer periphery of the pattern at a base of the varied cross-section mold, the varied cross-section mold forms a mold with a ratio between a top to a base thereof that is about 3:1.14. The varied cross-section mold as recited in claim 13 , wherein the varied cross-section mold is of a trapezoidal prism shape.15. (canceled)16. (canceled)17. A varied cross-section mold claim 13 , comprising:a trapezoidal prism shape with a pour cone in a top, the top larger than the base, wherein the varied cross-section mold forms a mold with a ratio between the top to the base thereof that is about 3:1.18. The varied cross-section mold as recited in claim 17 , wherein a mold thickness adjacent to an outer periphery of a pattern at a top of the varied cross-section mold is between 200-500% a thickness between the outer periphery of the pattern at a base of the varied cross-section mold.19. (canceled)20. The varied cross-section mold as recited in claim 17 , wherein the varied cross-section mold contains a rectangular pattern. This application is a Divisional of U.S. patent application Ser. No. 14/755,025, filed Jun. ...

Method for magnetic flux compensation in a directional solidification furnace utilizing an actuated secondary coil

A process for directional solidification of a cast part comprises energizing a primary inductive coil coupled to a chamber having a mold containing a material; generating an electromagnetic field with the primary inductive coil within the chamber, wherein said electromagnetic field is partially attenuated by a susceptor coupled to said chamber between said primary inductive coil and said mold; determining a magnetic flux profile of the electromagnetic field after it passes through the susceptor; sensing a component of the magnetic flux in the interior of the susceptor proximate the mold; positioning a mobile secondary compensation coil within the chamber; generating a control field from a secondary compensation coil, wherein said control field controls said magnetic flux; and casting the material within the mold.

Casting core removal through thermal cycling

A method of removing a core of a cast component includes providing a casting that includes a silica based ceramic core in a temperature controlled closed volume; cycling temperature between a first temperature and a second temperature within the temperature controlled closed volume that repeatedly subjects the silica based ceramic core to a beta-to-alpha cristobalite transition that induces microfractures in the silica based ceramic core; and after the cycling temperature, chemically dissolving the silica based ceramic core from the casting.

CAST PLATE HEAT EXCHANGER AND METHOD OF MAKING USING DIRECTIONAL SOLIDIFICATION

A cast part includes an outermost wall, at least one inner wall defining at least two internal passages and at least one cast cooling fin extending from an outer surface. The cooling fin includes a ratio of fin height to an average fin thickness that is greater than 2.0 and no more than 18.0. A method is also disclosed. 1. A cast part comprising:an outermost wall; andat least one inner wall defining at least two internal passages; andat least one cast cooling fin extending from an outer surface, wherein the cooling fin includes a ratio of fin height to an average fin thickness that is greater than 2.0 and no more than 18.0.2. The cast part as recited in claim 1 , wherein the ratio of the fin height to the average fin thickness is greater than 3.5 and no more than 12.0.3. The cast part as recited in claim 1 , including at least a first plate portion separated by an open space from a second plate portion claim 1 , wherein each of the first plate portion and the second plate portion include at least one cast cooling fin that extends into the open space.4. The cast part as recited in claim 3 , wherein a ratio of a first distance between outer surfaces of the first plate portion and the second plate portion bounding the open space and a second distance between a tip of at least one cast cooling fin is greater than 2.5 and no more than 4.5.5. The cast part as recited in claim 4 , wherein the ratio of the first distance to the second distance is greater than 3.25 and no more than 3.75.6. The cast part as recited in claim 1 , wherein the at least one cast fin includes a fin thickness that varies in a direction from a fin base toward a fin tip according to an angle from a plane normal to the outer surface that is greater than 0 and no more than 4 degrees.7. The cast part as recited in claim 1 , including at least one plate portion wherein the outer surface includes a top surface and a bottom surface and a plurality of the cast cooling fins extend from both the top surface ...

Method to prevent gap in cylindral seeds around an internal ceramic core

A process for casting a single crystal axis-symmetric thick walled tube comprising forming a axisymmetric single crystal ring seed around a circular internal core, wherein the ring seed has an inner diameter and a taper on the inner diameter, and wherein the internal core has an outer diameter and a matching taper on the outer diameter, the matching taper matching the taper of the inner diameter of the ring seed, and the internal core being free to translate in a vertical direction relative to the ring seed; and heating the ring seed so as to expand the ring seed relative to the internal core, and allowing the circular internal core to translate relative to the ring seed in a direction of the force of gravity, thereby maintaining contact between the circular internal core and the ring seed.

Chill Plate for Equiax Casting Solidification Control For Solid Mold Casting of Reticulated Metal Foams

A method to manufacture reticulated metal foam via a dual investment solid mold includes pouring molten metal material into a mold while the mold is located on a chill plate. A method to manufacture reticulated metal foam includes pouring molten metal material into a mold while the mold is located on a chill plate, the chill plate configured to apply an externally driven temperature gradient in the mold so that solidification progresses from the chilled end to the non-chilled end 1. A method to manufacture reticulated metal foam , comprising:pre-investing a precursor with a pre-investment ceramic plaster to encapsulate the precursor;investing the encapsulated precursor with a ceramic plaster to form a mold; andpouring molten metal material into the mold while the mold is located on a chill plate.2. (canceled)3. The method as recited in claim 1 , wherein the precursor is a reticulated foam structure.4. The method as recited in claim 1 , wherein the precursor is a polyurethane reticulated foam structure.5. The method as recited in claim 1 , wherein the precursor is completely encapsulated with the pre-investment ceramic plaster.6. The method as recited in claim 1 , further comprising claim 1 , coating the precursor in a molten wax to increase ligament thickness.7. The method as recited in claim 1 , further comprising claim 1 , coating the precursor in a molten wax to increase ligament thickness to provide an about 90% air to 10% precursor ratio.8. The method as recited in claim 1 , wherein the ceramic plaster is more rigid than the pre-investment ceramic plaster.9. The method as recited in claim 1 , wherein the diluted pre-investment ceramic plaster is about 55:100 water to powder ratio.10. The method as recited in claim 1 , wherein the ceramic plaster is about 28:100 water to powder ratio.11. The method as recited in claim 1 , wherein the chill plate operates at about room temperature.12. The method as recited in claim 11 , wherein the molten metal material is at a ...

Multi-layer susceptor design for magnetic flux shielding in directional solidification furnaces

An induction furnace assembly comprising a chamber having a mold; a primary inductive coil coupled to the chamber; a layered susceptor comprising at least two layers of magnetic field attenuating material surrounding the chamber between the primary inductive coil and the mold to nullify the electromagnetic field in the hot zone of the furnace chamber.

Dual Investment Shelled Solid Mold Casting of Reticulated Metal Foams

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

Method for magnetic flux compensation in a directional solidification furnace utilizing a stationary secondary coil

A process for directional solidification of a cast part comprises energizing a primary inductive coil coupled to a chamber having a mold containing a material; energizing a primary inductive coil within the chamber to heat the mold via radiation from a susceptor, wherein the resultant electromagnetic field partially leaks through the susceptor coupled to the chamber between the primary inductive coil and the mold; determining a magnetic flux profile of the electromagnetic field; sensing a magnetic flux leakage past the susceptor within the chamber; generating a control field from a secondary compensation coil coupled to the chamber, wherein the control field controls the magnetic flux experienced by the cast part; and casting the material within the mold under the controlled degree of flux leakage.

Dual investment shelled solid mold casting of reticulated metal foams

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

Variable diameter investment casting mold for casting of reticulated metal foams

A method to manufacture reticulated metal foam via a dual investment solid mold, includes pre-investing a precursor with a diluted pre-investment ceramic plaster to encapsulate the precursor; and investing the encapsulated precursor with a ceramic plaster within an mold of a varied cross-section. A varied cross-section mold includes a mold thickness adjacent to an outer periphery of a pattern at a top of the varied cross-section mold is between 200-500% a thickness between the outer periphery of the pattern at a base of the varied cross-section mold. A varied cross-section mold includes a trapezoidal prism shape with a pour cone in a top, the top larger than the base.

Chill plate for equiax casting solidification control for solid mold casting of reticulated metal foams

A method to manufacture reticulated metal foam via a dual investment solid mold includes pouring molten metal material into a mold while the mold is located on a chill plate. A method to manufacture reticulated metal foam includes pouring molten metal material into a mold while the mold is located on a chill plate, the chill plate configured to apply an externally driven temperature gradient in the mold so that solidification progresses from the chilled end to the non-chilled end.

Multi-layer susceptor design for magnetic flux shielding in directional solidification furnaces

An induction furnace assembly comprising a chamber having a mold; a primary inductive coil coupled to the chamber; a layered susceptor comprising at least two layers of magnetic field attenuating material surrounding the chamber between the primary inductive coil and the mold to nullify the electromagnetic field in the hot zone of the furnace chamber.

Method for magnetic flux compensation in a directional solidification furnace utilizing an actuated secondary coil

A process for directional solidification of a cast part comprises energizing a primary inductive coil coupled to a chamber having a mold containing a material; generating an electromagnetic field with the primary inductive coil within the chamber, wherein said electromagnetic field is partially attenuated by a susceptor coupled to said chamber between said primary inductive coil and said mold; determining a magnetic flux profile of the electromagnetic field after it passes through the susceptor; sensing a component of the magnetic flux in the interior of the susceptor proximate the mold; positioning a mobile secondary compensation coil within the chamber; generating a control field from a secondary compensation coil, wherein said control field controls said magnetic flux; and casting the material within the mold.

Variable diameter investment casting mold of reticulated metal foams

Systems, formulations, and methods for removal of ceramic cores from turbine blades after casting

A solution is provided includes a strong base, a corrosion inhibitor, wherein the strong base is an alkali metal hydroxide, wherein the corrosion inhibitor is at least one of an organic acid having a-COOH functional group or an alkali metal salt of one of an organic acid having a-COOH functional group.

Arcuate seed casting method

A casting method includes: forming a seed, the seed having a first end and a second end, the forming including bending a seed precursor; placing the seed second end in contact or spaced facing relation with a chill plate; contacting the first end with molten material; and cooling and solidifying the molten material so that a crystalline structure of the seed propagates into the solidifying material. The forming further included reducing a thickness of the seed proximate the first end relative to a thickness of the seed proximate the second end.

Arcuate seed casting method

A casting method includes forming a seed (20, 800). The seed has a first end (24) and a second end (22) and an inner diameter (ID) surface (34) and an outer diameter (OD) surface (36). The seed second end (22) is placed in contact or spaced facing relation with a chill plate (102). The first end (24) is contacted with molten material (50). The molten material is cooled and solidified so that a crystalline structure of the seed (20) propagates into the solidifying material (50). At least a portion of the seed (20) contacted with the molten material (50) has a solidus higher than a solidus of at least an initial pour portion (910) of the molten material (50).

Arcuate seed casting method

Cast plate heat exchanger and method of making using directional solidification

Cast plate heat exchanger and method of making using directional solidification

A cast part includes an outermost wall, at least one inner wall defining at least two internal passages and at least one cast cooling fin extending from an outer surface. The cooling fin includes a ratio of fin height to an average fin thickness that is greater than 2.0 and no more than 18.0. A method is also disclosed.

Arcuate seed casting method

Cast plate heat exchanger and method of making using directional solidification

A cast part (12) includes an outermost wall (65), at least one inner wall (40a, 40b, 40c) defining at least two internal passages (28) and at least one cast cooling fin (24) extending from an outer surface (90A, 90B). The cooling fin (24) includes a ratio of fin height (104) to an average fin thickness (92) that is greater than 2.0 and no more than 18.0. A method is also disclosed.

Method of wall control in multi-wall investment casting

A casting method includes passing a metallic spacer through respective apertures in at least two ceramic cores to an installed condition wherein the spacer defines a minimum local separation between the at least two cores. The spacer has a shank and at least one arm extending from the shank. A sacrificial pattern material is molded over the metallic spacer and the at least two ceramic cores and then shelled and fired. An alloy is cast in the shell the shell is removed from the cast alloy.

Arcuate seed casting method

A casting method includes forming a seed. The seed has a first end and a second end and an inner diameter (ID) surface and an outer diameter (OD) surface. The seed second end is placed in contact or spaced facing relation with a chill plate. The first end is contacted with molten material. The molten material is cooled and solidified so that a crystalline structure of the seed propagates into the solidifying material. At least a portion of the seed contacted with the molten material has a solidus higher than a solidus of at least an initial pour portion of the molten material.

Arcuate seed casting method

A casting method includes: forming a seed (20), the seed having a first end (24) and a second end (22), the forming including bending a seed precursor; placing the seed second end in contact or spaced facing relation with a chill plate (102); contacting the first end with molten material (50); and cooling and solidifying the molten material so that a crystalline structure of the seed propagates into the solidifying material. The forming further included reducing a thickness (T_U) of the seed proximate the first end relative to a thickness (T₁) of the seed proximate the second end.

Arcuate seed casting method

A casting method includes forming a seed (20, 800). The seed has a first end (24) and a second end (22) and an inner diameter (ID) surface (34) and an outer diameter (OD) surface (36). The seed second end (22) is placed in contact or spaced facing relation with a chill plate (102). The first end (24) is contacted with molten material (50). The molten material is cooled and solidified so that a crystalline structure of the seed (20) propagates into the solidifying material (50). At least a portion of the seed (20) contacted with the molten material (50) has a solidus higher than a solidus of at least an initial pour portion (910) of the molten material (50).

Arcuate seed casting method

A casting method includes: forming a seed (20), the seed having a first end (24) and a second end (22), the forming including bending a seed precursor; placing the seed second end in contact or spaced facing relation with a chill plate (102); contacting the first end with molten material (50); and cooling and solidifying the molten material so that a crystalline structure of the seed propagates into the solidifying material. The forming further included reducing a thickness (T U ) of the seed proximate the first end relative to a thickness (T 1 ) of the seed proximate the second end.

Arcuate Seed Casting Method

A casting method includes: forming a seed, the seed having a first end and a second end, the forming including bending a seed precursor; placing the seed second end in contact or spaced facing relation with a chill plate; contacting the first end with molten material; and cooling and solidifying the molten material so that a crystalline structure of the seed propagates into the solidifying material. The forming further included reducing a thickness of the seed proximate the first end relative to a thickness of the seed proximate the second end.

Cast plate heat exchanger and method of making using directional solidification

A cast part (12) includes an outermost wall (65), at least one inner wall (40a, 40b, 40c) defining at least two internal passages (28) and at least one cast cooling fin (24) extending from an outer surface (90A, 90B). The cooling fin (24) includes a ratio of fin height (104) to an average fin thickness (92) that is greater than 2.0 and no more than 18.0. A method is also disclosed.

Cast plate heat exchanger and method of making using directional solidification

A cast part includes an outermost wall, at least one inner wall defining at least two internal passages and at least one cast cooling fin extending from an outer surface. The cast part including a cross-sectional circular area spanning at least a portion of each of four internal passages includes a ratio of interior empty space to inner wall space that improves heat transfer.

Arcuate seed casting method

A casting method includes forming a seed (20). The seed has a first end (24) and a second end (22). The forming includes bending a seed precursor. The seed second end (22) is placed in contact or spaced facing relation a chill plate (102). The first end is contacted with molten material (50). The molten material (50) is cooled and solidifies so that a crystalline structure of the seed (20) propagates into the solidifying material (50). The forming further includes inserting the bent seed precursor into a sleeve (252, 292, 302) leaving the bent seed precursor (254, 297, 304) protruding from a first end of the sleeve.

Arcuate seed casting method

Arcuate Seed Casting Method

A casting method includes forming a seed. The seed has a first end and a second end. The forming includes bending a seed precursor. The seed second end is placed in contact or spaced facing relation a chill plate. The first end is contacted with molten material. The molten material is cooled and solidifies so that a crystalline structure of the seed propagates into the solidifying material. The forming further includes inserting the bent seed precursor into a sleeve leaving the bent seed precursor protruding from a first end of the sleeve.

Arcuate seed casting method

A casting method includes forming a seed (20). The seed has a first end (24) and a second end (22). The forming includes bending a seed precursor. The seed second end (22) is placed in contact or spaced facing relation a chill plate (102). The first end is contacted with molten material (50). The molten material (50) is cooled and solidifies so that a crystalline structure of the seed (20) propagates into the solidifying material (50). The forming further includes inserting the bent seed precursor into a sleeve (252, 292, 302) leaving the bent seed precursor (254, 297, 304) protruding from a first end of the sleeve.

Arcuate seed casting method

A casting method includes forming a seed. The seed has a first end and a second end. The forming includes bending a seed precursor. The seed second end is placed in contact or spaced facing relation a chill plate. The first end is contacted with molten material. The molten material is cooled and solidifies so that a crystalline structure of the seed propagates into the solidifying material. The forming further includes inserting the bent seed precursor into a sleeve leaving the bent seed precursor protruding from a first end of the sleeve.

Systems, formulations, and methods for removal of ceramic cores from turbine blades after casting

A solution is provided and includes a strong base, a corrosion inhibitor, wherein the strong base is an alkali metal hydroxide, wherein the corrosion inhibitor is at least one of an organic acid having a-COOH functional group or an alkali metal salt of one of an organic acid having a-COOH functional group.