Casting method and mold design for optimization of material properties of a casting

Abstract

A casting method and mold design for optimization of material properties of a casting is disclosed, wherein the optimization is accomplished through control of a cooling rate of the casting to provide desired material properties throughout the casting.

Description

FIELD OF THE INVENTION [0001] The invention relates to casting and more particularly to a casting method and mold design for optimization of material properties of a casting, wherein the optimization is accomplished through control of a cooling rate of the casting. BACKGROUND OF THE INVENTION [0002] In a casting process, variations in material properties can occur in different regions within a casting. Amongst other reasons, the variations can occur when the different regions of the casting are permitted to cool, and thus solidify, at different rates. Castings having complicated geometries are particularly susceptible to these variations since the cooling rates in the various regions of the casting are geometry dependant. For example, in a region having a high ratio of local surface area to volume, the faster the region will tend to cool. In a region having a low ratio of local surface area to volume, the slower the region will tend to cool. This results in material properties which...

AI Technical Summary

Benefits of technology

[0006] In one embodiment, the casting apparatus comprises a first mold pattern for forming a first mold cavity for receiving a molten material therein; and a second mold pattern positioned adjacent at least a portion of said first mold pattern, said second mold pattern forming a second mold cavity for receiving the molten material therein, wherein the molten material in the second mold cavity controls a cooling rate of the molten material in the portion of the first mold cavity.

[0007] In another embodiment, a mold for casting comprises a mold having a first mold cavity and a second mold cavity formed therein and adapted to receive a molten material, the second mold cavity formed adjacent at least a portion of the first mold cavity, wherein the molten material received in the second mold cavity controls a cooling rate of the molten material received in the portion of the first mold cavity adjacent the second mold cavity.

[0008] The invention also provides a method of controlling the cooling rate of molten material in a casting process that comprises the steps of providing a first mold pattern for forming a first mold cavity for receiving a molten material; providing a second mold pattern for forming a second mold cavity for receiving a molten material; positioning the second mold pattern adjacent at least a portion of the first mold pattern; and introducing molten material into the first mold cavity and the second mold cavity, wherein the molten material in the second mold cavity controls the cooling rate of the molten material in the portion of the first mold cavity.

Problems solved by technology

Castings having complicated geometries are particularly susceptible to these variations since the cooling rates in the various regions of the casting are geometry dependant.

Such variations in material properties within a casting are often undesirable.

The variations can cause problems with machinability or other processing.

Issues with product performance can also arise.

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