Patent application number | Description | Published |
20090114797 | REFRACTORY METAL CORE COATINGS - A refractory metal core for use in a casting system has a coating for providing oxidation resistance during shell fire and protection against reaction/dissolution during casting. In a first embodiment, the coating includes at least one oxide and a silicon containing material. In a second embodiment, the coating includes an oxide selected from the group of calcia, magnesia, alumina, zirconia, chromia, yttria, silica, hafnia, and mixtures thereof. In a third embodiment, the coating includes a nitride selected from the group of silicon nitride, sialon, titanium nitride, and mixtures thereof. Other coating embodiments are described in the disclosure. | 05-07-2009 |
20120175075 | Preformed ceramic seed well for single crystal starter seed - A method of creating an article from investment casting includes forming a ceramic seed well, heating the ceramic seed well to form a hardened ceramic seed well, attaching a meltable pattern to the hardened ceramic seed well, coating the hardened ceramic seed well and the meltable pattern with hardenable ceramic material, heating the hardenable ceramic material to melt the meltable pattern, removing the meltable pattern from the hardenable ceramic material, firing the hardenable ceramic material to form a ceramic mold having a cavity, placing a seed within the hardened ceramic seed well, and pouring molten metal into the hardened ceramic seed well and the cavity. The cavity of the ceramic mold is in communication with the hardened ceramic seed well. | 07-12-2012 |
20150328681 | Multi-Shot Casting - An alloy part is cast in a mold ( | 11-19-2015 |
Patent application number | Description | Published |
20100000698 | CASTING SYSTEM FOR INVESTMENT CASTING PROCESS - A casting system includes a core and a shell positioned relative to the core. A barrier coating is applied on at least one of the core and the shell. | 01-07-2010 |
20100084106 | PROCESS FOR CASTING COLUMNAR GRAIN AIRFOIL WITH PREFERENTIAL PRIMARY ORIENTATION - A molding process utilizes a seed with a columnar grain structure for defining a desired grain structure in a completed casting. The seed is received within a seed cavity of a mold. The molten material adopts the orientation of the columns defined within the seed during solidification to form a completed molded article having a desired columnar grain structure. | 04-08-2010 |
20100238967 | METHOD OF PRODUCING A FINE GRAIN CASTING - An induction heated furnace assembly for producing a directionally solidified casting includes a susceptor that tailors strength of the magnetic field within the chamber to provide a desired grain structure in a completed cast part. The susceptor proportionally blocks portions of the magnetic field to provide different levels of magnetic stirring within the molten material at different locations within the furnace assembly stirring induced by the magnetic field is controlled and varied throughout the furnace assembly to create the desired grain structures in the completed cast article. | 09-23-2010 |
20100247322 | INTERNALLY SUPPORTED AIRFOIL AND METHOD FOR INTERNALLY SUPPORTING A HOLLOW AIRFOIL DURING MANUFACTURING - A hollow airfoil and a method for manufacturing a hollow airfoil is provided. The method includes the steps of: providing a first airfoil portion, which first portion has a wall with an interior surface and an exterior surface, and one or more ribs extending out from the interior surface; providing a second airfoil portion having a wall with an interior surface and an exterior surface; wherein the first airfoil portion and the second airfoil portion have mating geometries in which the one or more ribs extend between the interior surfaces of the walls of the first and second airfoil portion to form at least one internal cavity defined by the interior surface of the first portion wall, one or more of the ribs, and the interior surface of the second portion wall, and wherein the airfoil includes at least one exterior port disposed in one of the first airfoil portion or the second airfoil portion, or is formed between the first and second airfoil portions, which at least one exterior port is in fluid communication with the at least one cavity; disposing a support material within the at least one internal cavity allowing the support material to be in contact with the one or more ribs, which support material is operative to structurally support the one or more ribs; attaching the first and second airfoil portions together; and removing the support material from the at least one internal cavity through the at least one exterior port. | 09-30-2010 |
20110186258 | FORMING A CAST COMPONENT WITH AGITATION - A method of forming a cast component includes at least partially surrounding an investment mold in a heat-insulating packing material, feeding a molten alloy into the investment mold to provide a filled investment mold, and agitating the filled investment mold while solidifying the molten alloy. | 08-04-2011 |
20120043046 | PROCESS FOR CASTING COLUMNAR GRAIN AIRFOIL WITH PREFERENTIAL PRIMARY ORIENTATION - A molding process utilizes a seed with a columnar grain structure for defining a desired grain structure in a completed casting. The seed is received within a seed cavity of a mold. The molten material adopts the orientation of the columns defined within the seed during solidification to form a completed molded article having a desired columnar grain structure. | 02-23-2012 |
20120110813 | DIE CASTING SYSTEM AND METHOD UTILIZING SACRIFICIAL CORE - A method for die casting a component includes inserting at least one sacrificial core into a die cavity of a die comprised of a plurality of die elements. Molten metal is injected into the die cavity. The molten metal is solidified within the die cavity to form the component. The plurality of die elements are disassembled from the component, and the at least one sacrificial core is destructively removed from the component. | 05-10-2012 |
20120111523 | MELTING UNIT FOR A DIE CASTING SYSTEM - A die casting system includes a die, a shot tube, a shot tube plunger and a melting unit. The die includes a plurality of die components that define a die cavity. The shot tube is in fluid communication with the die cavity. A shot tube plunger is moveable within the shot tube to communicate a charge of material into the die cavity. The melting unit is positioned relative to the die and includes a bottom portion having an opening for selectively releasing a charge of material through the bottom portion. | 05-10-2012 |
20120111526 | DIE CASTING SYSTEM AND METHOD UTILIZING HIGH MELTING TEMPERATURE MATERIALS - An example die casting system includes a die comprised of a plurality of die components that define a die cavity configured to receive a molten metal. One of the die components comprises a material that is not reactive with the molten metal and has a melting temperature above 815 degrees Celsius. | 05-10-2012 |
20120112391 | CRUCIBLE FOR MASTER ALLOYING - A crucible includes a composite of least two materials. The two materials are selected from a group consisting of alumina, calcia, yttria, erbia, gadolinia, magnesia, hafnia, and zirconia in a composition that has better resistance to reaction with hafnium from a molten hafnium-containing alloy than a nominal crucible composition of 70 wt % magnesia and 30 wt % alumina. | 05-10-2012 |
20120211193 | DIE CASTING SYSTEM AND CELL - A die casting system includes a die, a shot tube, a melting system and a vacuum system. The die includes a plurality of die components that define a die cavity. The shot tube is in fluid communication with the die cavity and is operable to deliver a charge of material to the die cavity. The melting system is positioned adjacent to the die and includes an alloy loader, a melting unit and a crucible. The vacuum system defines a first chamber and a second chamber separated from the first chamber by an isolation valve. The melting system is disposed within the first chamber, and the die is disposed within the second chamber. | 08-23-2012 |
20130025810 | RAPID MANUFACTURING METHOD - A rapid manufacturing method includes forming tooling in a rapid manufacturing process. The tooling is coated with a conductive material. | 01-31-2013 |
20130025816 | DIE CASTING SYSTEM AND METHOD - A die casting system includes a die having a plurality of die elements that define a die cavity. A charge of material is received in the die cavity. The charge of material may comprises a refractory metal intermetallic composite based material system. The charge of material may also comprise a composite material. | 01-31-2013 |
20130026338 | RAPID CASTING ARTICLE MANUFACTURING - A method of manufacturing a casting article for use in a casting process includes rapidly forming the casting article out of a metallic material. A ceramic coating is applied to an exterior surface of the casting article. | 01-31-2013 |
20130081775 | METHOD AND SYSTEM FOR DIE CASTING A HYBRID COMPONENT - A method for die casting a hybrid component includes defining a cavity within a die element of a die and inserting a spar into the cavity. Molten metal is injected into the die element. The molten metal is solidified within the cavity to cast the hybrid component. The spar establishes an internal structure of the hybrid component. The spar includes a high melting temperature material that defines a first melting temperature greater than a second melting temperature of the molten metal. | 04-04-2013 |
20130171020 | HIGH TEMPERATURE DIRECTIONALLY SOLIDIFIED AND SINGLE CRYSTAL DIE CASTING - A high-temperature die casting apparatus comprises a die and a chiller. The die has a first die plate and a second die plate with respective first and second recesses defining a main part cavity and gating. The apparatus can be used for die casting metal alloys having a melting temperature of at least about 1500° F. (about 815° C.). | 07-04-2013 |
20140060708 | High Elastic Modulus Shafts and Method of Manufacture - High modulus turbine shafts and high modulus cylindrical articles are described as are the process parameters for producing these shafts and cylindrical articles. The shafts/articles have a high Young's modulus as a result of having high modulus <111> crystal texture along the longitudinal axis of the shaft/article. The shafts are produced from directionally solidified seeded <111> single crystal cylinders that are axisymmetrically hot worked before a limited recrystallization process is carried out at a temperature below the recrystallization temperature of the alloy. The disclosed process produces an intense singular <111> texture and results in shaft or cylindrical article with a Young's modulus that is at least 40% greater than that of conventional nickel or iron alloys or conventional steels. | 03-06-2014 |
20140166229 | Minimization of Re-Crystallization in Single Crystal Castings - A refractory metal core for forming internal features in a turbine engine component has a core formed from a refractory metal material; and the core has at least one blended surface on at least one edge of the core. | 06-19-2014 |
20140178244 | GASEOUS BASED DESULFURIZATION OF ALLOYS - A method for desulfurizing a metal alloy comprises heating the metal alloy to a molten state. A gaseous desulfurizing compound is bubbled through the molten alloy to form a solid sulfur-containing waste phase and a molten reduced-sulfur alloy phase. The solid waste phase and the molten reduced-sulfur alloy phase are separated. The gaseous desulfurizing compound includes a constituent element selected from the group: alkali metals, alkaline earth metals, and rare earth metals. | 06-26-2014 |
20140205493 | HIGH TEMPERATURE DIRECTIONALLY SOLIDIFIED AND SINGLE CRYSTAL DIE CASTING - A high-temperature die casting die includes a first die plate with a first recess and a second die plate with a second recess, the first and second recesses defining a main part cavity and gating. A grain selector is in fluid communication with the main cavity, and an in situ zone refining apparatus is adapted to apply a localized thermal gradient to at least one of the first and second die plates. The localized thermal gradient and the at least one die plate are movable relative to each other so as to apply the localized thermal gradient along a first direction extending from the grain selector longitudinally across the main part cavity. | 07-24-2014 |
20140338854 | DIE CASTING SYSTEM AND METHOD UTILIZING SACRIFICIAL CORE - A method for die casting a component includes inserting at least one sacrificial core into a die cavity of a die comprised of a plurality of die elements. Molten metal is injected into the die cavity. The molten metal is solidified within the die cavity to form the component. The plurality of die elements are disassembled from the component, and the at least one sacrificial core is destructively removed from the component. | 11-20-2014 |
20150060002 | DIE CASTING SYSTEM AND CELL - A method of manufacturing a component in a die casting cell that includes a die casting system according to an exemplary aspect of the present disclosure includes, among other things, isolating a first chamber from a second chamber of the die casting system, melting a charge of material in the first chamber, sealing the second chamber relative to the first chamber, and simultaneously injecting the charge of material within the second chamber to cast the component and melting a second charge of material within the first chamber. | 03-05-2015 |
20150096713 | RAPID TOOLING INSERT MANUFACTURE - A method of fabricating a die cast article is disclosed and includes forming an insert with an additive manufacturing process to define a cavity for generating desired part geometry. The insert is then mounted within a mold tool, material is injected into the cavity to fill the cavity and form a cast article. | 04-09-2015 |
20150158076 | METHOD OF FABRICATING AN INVESTMENT CASTING MOLD AND SLURRY THEREFOR - A method of fabricating an investment casting mold includes using a zircon-containing slurry to form a facecoat of a refractory investment wall of a mold cavity in an investment casting mold. The zircon-containing slurry includes, by weight, at least 70% of zircon powder. Also disclosed is a slurry for use in an investment casting mold. The slurry includes, by weight, at least 70% of zircon powder, 10%-30% of colloidal silica material, and 1%-10% of a carrier solvent. The method and slurry can be used to fabricate an investment casting mold that has a refractory investment wall with a facecoat having, by weight, at least 70% zircon. | 06-11-2015 |
20150174653 | SYSTEM AND METHODS FOR REMOVING CORE ELEMENTS OF CAST COMPONENTS - A system and methods are provided for removing core elements of cast components. In one embodiment, a method includes controlling a first high temperature autoclave cycle for a cast component in a vessel with a first solution concentration to remove at least a first portion of core elements, wherein the first solution concentration, temperature and pressure in the vessel are controlled to expose one or more casting pins in the cast component. The method may also include controlling a second high temperature autoclave cycle for the cast component in the vessel with second solution concentration, wherein the second solution concentration, temperature and pressure in the vessel during the second high temperature autoclave cycle are controlled to loosen one or more of the casting pins from the cast component, and controlling one or more low temperature autoclave cycles to remove core and casting pins from the cast component. | 06-25-2015 |
Patent application number | Description | Published |
20120292259 | SYSTEM AND METHOD FOR TREATMENT OF PRODUCED WATERS CONTAINING GEL - This disclosure describes novel systems and methods for removing gel from flowback water. The methods and systems include treating acidified flowback water with aluminum chlorohydrate. | 11-22-2012 |
20130313199 | SYSTEM AND METHOD FOR TREATMENT OF PRODUCED WATERS - The systems and methods disclosed herein process produced/flowback water, such as high total dissolved solids produced water, to generate high purity, high value products with little to no waste. The generated high purity, high value products include caustic soda, hydrochloric acid, and/or sodium hypochlorite. Further, the methods and systems disclosed herein generate high quality brine for electrolysis through the systematic removal of contaminants such as but not limited to suspended solids, iron, sulfides, barium, radium, strontium, calcium, magnesium, manganese, fluoride, heavy metals, organic carbon, recoverable hydrocarbons, silica, lithium, and/or nitrogen containing compounds. Further, some products generated by the systems and methods disclosed herein may be recovered and reutilized or sold for other uses, such as carbon dioxide, calcium oxide, chlorine, magnesium oxide, calcium carbonate, and barium sulfate. | 11-28-2013 |
20140069821 | SYSTEM AND METHOD FOR TREATMENT OF PRODUCED WATERS - The systems and methods disclosed herein process produced/flowback water, such as high total dissolved solids produced water, to generate high purity, high value products with little to no waste. The generated high purity, high value products include caustic soda, hydrochloric acid, and/or sodium hypochlorite. Further, the methods and systems disclosed herein generate high quality brine for electrolysis through the systematic removal of contaminants such as but not limited to suspended solids, iron, sulfides, barium, radium, strontium, calcium, magnesium, manganese, fluoride, heavy metals, organic carbon, recoverable hydrocarbons, silica, lithium, and/or nitrogen containing compounds. Further, some products generated by the systems and methods disclosed herein may be recovered and reutilized or sold for other uses, such as carbon dioxide, calcium oxide, chlorine, magnesium oxide, calcium carbonate, and/or barium sulfate. | 03-13-2014 |