Method of casting a metal article
a metal article and metal technology, applied in the field of metal article casting, can solve the problems of relatively low thermal conductivity of inert gas,
Inactive Publication Date: 2010-06-03
PCC AIRFOILS
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Benefits of technology
The present invention is a new and improved method of casting metal articles. It involves filling a mold with molten metal while it is in a furnace and then lowering it in a body of inert gas. The invention includes a feature where a stream of coolant is directed against the mold to initiate solidification of the molten metal in the first portion of the mold. This stream can be formed of molten metal or inert gas with particulate entrained. The invention has various advantages that can be used together or separately.
Problems solved by technology
However, an inert gas has a relatively low thermal conductivity.
The low thermal conductivity of an inert gas does not promote heat transfer to initiate solidification of molten metal in the mold.
Method used
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[0011]An improved casting apparatus 10 is illustrated schematically in FIG. 1 and is utilized in an improved method of casting metal articles in a mold structure 12. The casting apparatus 10 includes a furnace assembly 16 in which a molten metal is poured into the ceramic mold structure 12 in a known manner. Directly beneath the furnace assembly 16 is a container 20 into which the mold structure 12 is lowered from the furnace assembly 16. The furnace assembly 16 and container 20 are enclosed by a suitable housing 24 which is connected with a source of vacuum or low pressure by a conduit 26. The housing 24 is connected with a source of an inert gas, such as argon, by a conduit 27.
[0012]The housing 24 enables the body 28 of inert gas to be maintained in the container 20. The housing 24 may have any one of many known constructions, including the construction disclosed in U.S. Pat. No. 3,841,384 and / or the construction shown in U.S. Pat. No. 6,308,767. Of course, the housing 24 may have...
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Abstract
During the casting of the metal article, a mold is lowered from a furnace assembly into a body of an inert gas. A stream having a thermal conductivity greater than the thermal conductivity of the inert gas is directed against a first portion of the mold to initiate solidification of molten metal in the first portion of the mold. The stream is subsequently directed against portions of the mold disposed in the body of inert gas and disposed above the first portion of the mold to initiate solidification of molten metal and portions of the mold above the first portion of the mold. The stream may be formed of a molten metal. Alternatively, the stream may be formed of an inert gas in which particulate is entrained.
Description
BACKGROUND OF THE INVENTION[0001]The present invention relates to a new and improved method of casting a metal article.[0002]It has previously been suggested that a casting apparatus may employ a body of molten metal or a fluidized bed as a cooling bath to promote directional solidification of an article in a mold. Apparatus for doing this is disclosed in U.S. Pat. No. 6,308,767 and U.S. Pat. No. 6,695,034. When a mold is immersed in a bath of molten metal, in the manner disclosed in U.S. Pat. No. 6,308,767, there is a tendency for stress to develop in the cast metal article due to differential thermal contraction.[0003]It has also been suggested that a flow of inert gas be directed against a mold to promote directional solidification of metal in the mold. An apparatus for doing this is disclosed in U.S. Pat. No. 7,017,646. However, an inert gas has a relatively low thermal conductivity. The low thermal conductivity of an inert gas does not promote heat transfer to initiate solidifi...
Claims
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IPC IPC(8): B22D27/04
CPCB22D27/045
Inventor GRAHAM, LAWRENCE D.
Owner PCC AIRFOILS