Hybrid setter for investment casting cores and method of use

Abstract

A setter for an investment casting core is provided. The setter may include a base section and a cover section configured to mechanically couple to the base section, the cover section having a contour for receiving an investment casting on the cover section. A setter array for a plurality of investment casting cores is also provided. A method for supporting an investment casting core using the setter during heat treatment is also provided.

Description

[Technical Field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims the benefit of priority to U.S. Patent Application No. 18 / 470,492, filed September 20, 2023, and U.S. Provisional Patent Application No. 63 / 376,636, filed September 22, 2022, the contents of each of which are hereby expressly incorporated by reference into this disclosure as if set forth in their entirety herein. [Background technology]

[0002] The present disclosure relates generally to setters, setter arrays, setter systems for investment casting cores and methods of using the same. In particular, the present disclosure relates generally to hybrid setters, setter arrays and setter systems for heat treating investment casting cores and methods of using them to support the investment casting cores during heat treating.

[0003] Due to the often complex geometric shape of investment casting cores, such as ceramic cores, setters with complementary profiles are typically used to minimize any distortion that may occur during heat treatment of the investment casting core. Like the investment casting core itself, the corresponding setter may also require very tight geometric tolerances. Thousands of different core designs may exist, and each different core may require a different setter, which in turn requires a different mold for each different setter. Furthermore, due to the tight geometric tolerances of the core and setter, if different materials are used for the core or setter, different molds must be used to account for the different shrinkage profiles of the materials during the heat treatment process. This leads to extensive mold inventory and long lead times, especially when new molds are required for customized investment casting cores. Summary of the Invention

[0004] Certain embodiments are summarized below. These embodiments are not intended to limit the scope of the disclosure; rather, these embodiments are intended only to provide a brief summary of possible forms of the disclosure. Indeed, the present system and method may encompass a variety of forms that may be similar to or different from the embodiments set forth below.

[0005] All aspects, examples and features described below may be combined in any technically possible manner.

[0006] One aspect of the present disclosure provides a setter for an investment casting core, the setter comprising a base section and a cover section configured to mechanically couple to the base section, the cover section having a contour for receiving the investment casting core on the cover section.

[0007] Another aspect of the present disclosure is a setter array for a plurality of investment casting cores, the setter array including a base section and a plurality of cover sections, each configured to mechanically couple to a respective portion of the base section, the plurality of cover sections having contours for receiving a respective one of the plurality of investment casting cores on the plurality of cover sections.

[0008] Yet another aspect of the present disclosure provides a method for supporting an investment casting core using a setter during heat treatment, the method including: providing a base section; mechanically coupling a cover section to the base section, the cover section including a contour for receiving the investment casting core on the cover section; and positioning the investment casting core on the cover section such that a surface of the investment casting core substantially mates with a portion of the contour of the cover section that receives the investment casting core on the cover section.

[0009] The details of one or more embodiments are set forth in the accompanying drawings and the description below. Other features, objects, and advantages will be apparent from the description and drawings, and from the claims.

[0010] These and other features of the present disclosure will be more readily understood from the following detailed description of the various aspects of the disclosure taken in conjunction with the accompanying drawings illustrating various embodiments of the disclosure. [Brief explanation of the drawings]

[0011] [Figure 1A] FIG. 1 is an exploded perspective view of a setter according to an embodiment of the present disclosure. [Figure 1B] 1B is an exploded perspective side view of the setter of FIG. 1A according to an embodiment of the present disclosure. [Figure 1C] 1B is an exploded side view of the setter of FIG. 1A with an investment casting core placed on the setter. FIG. [Figure 2A] FIG. 1 is an exploded perspective view of a setter including two sidewall extensions according to an embodiment of the present disclosure. [Figure 2B] FIG. 2B is a top view of the setter of FIG. 2A according to an embodiment of the present disclosure. [Figure 3A] FIG. 1 is an exploded perspective view of a setter including a complete sidewall extension according to an embodiment of the present disclosure. [Figure 3B] 3B is a top view of the setter of FIG. 3A showing the cover section received within the base section according to an embodiment of the present disclosure. [Figure 4A] FIG. 1 is an exploded perspective view of a setter including a base section including a semi-cylindrical portion according to an embodiment of the present disclosure. [Figure 4B] FIG. 4B is another exploded perspective view of the setter of FIG. 4A according to an embodiment of the present disclosure. [Figure 4C] 4B is a perspective view of the setter of FIG. 4A showing the cover section received within the base section according to an embodiment of the present disclosure. [Figure 5A] 1 is an exploded perspective view of a setter including a base section including a semi-cylindrical portion and a protrusion, and a cover section including a recess, according to an embodiment of the present disclosure; FIG. [Figure 5B] FIG. 5B is another exploded perspective view of the setter of FIG. 5A according to an embodiment of the present disclosure. [Figure 5C] 5B is a perspective view of the setter of FIG. 5A showing the cover section received within the base section according to an embodiment of the present disclosure. [Figure 6A] FIG. 1 is an exploded perspective view of a setter including a base section including a peripheral groove according to an embodiment of the present disclosure. [Figure 6B] FIG. 6B is a top perspective view of the setter of FIG. 6A according to an embodiment of the present disclosure. [Figure 7A] FIG. 1 is an exploded perspective view of a setter including a base section including a center portion and a lip surrounding the center portion, according to an embodiment of the present disclosure. [Figure 7B] FIG. 7B is a top perspective view of the setter of FIG. 7A according to an embodiment of the present disclosure. [Figure 8A] FIG. 1 is a perspective view of a setter including a base section including a dovetail edge according to an embodiment of the present disclosure. [Figure 8B] FIG. 8B is an exploded side view of the setter of FIG. 8A according to an embodiment of the present disclosure. [Figure 9A] FIG. 1 is an exploded perspective view of a setter including a base section including a dovetail edge according to an embodiment of the present disclosure. [Figure 9B] 9B is a perspective view of the setter of FIG. 9A showing the cover section received within the base section according to an embodiment of the present disclosure. [Figure 10A] FIG. 1 is an exploded perspective view of a setter including a cover section including a protrusion and a base section including a protrusion engagement structure according to an embodiment of the present disclosure. [Figure 10B] FIG. 10B is another exploded perspective view of the setter of FIG. 10A according to an embodiment of the present disclosure. [Figure 10C] FIG. 10B is a perspective side view of the setter of FIG. 10A according to an embodiment of the present disclosure. [Figure 11A] FIG. 1 is an exploded perspective view of a setter including a base section including a cutout according to an embodiment of the present disclosure. [Figure 11B]11B is another exploded perspective view of the setter of FIG. 11A showing the base section and the cover section including the locking unit according to an embodiment of the present disclosure. FIG. [Figure 11C] FIG. 11B is another exploded perspective view of the setter of FIG. 11A according to an embodiment of the present disclosure. [Figure 11D] FIG. 11B is an exploded bottom perspective view of the setter of FIG. 11A according to an embodiment of the present disclosure. [Figure 12A] FIG. 10 is an exploded perspective view of a setter array including a base section and multiple cover sections, illustrating matching contours of the multiple cover sections and corresponding portions of the base section, according to an embodiment of the present disclosure. [Figure 12B] FIG. 12B is another exploded perspective view of the setter array of FIG. 12A according to an embodiment of the present disclosure. [Figure 12C] FIG. 12B is a perspective view of the setter array of FIG. 12A showing a plurality of cover sections received within the base section according to an embodiment of the present disclosure. [Figure 13A] FIG. 1 is a perspective view of a setter array including a base section and a plurality of cover sections according to an embodiment of the present disclosure. [Figure 13B] FIG. 13B is a perspective side view of the setter array of FIG. 13A showing multiple cover sections received within the base section according to an embodiment of the present disclosure. [Figure 14] FIG. 1 is an exploded side view of a setter system including a first setter with an investment casting core sandwiched therebetween and a second setter according to an embodiment of the present disclosure. [Figure 15] FIG. 1 is a perspective side view of a setter system including a first setter with an investment casting core sandwiched therebetween and a second setter according to an embodiment of the present disclosure. [Figure 16] FIG. 1 is a flow diagram of a method for supporting an investment casting core using a setter according to an embodiment of the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0012] It should be noted that the drawings of the present disclosure are not necessarily to scale. The drawings are intended to depict only typical aspects of the disclosure and therefore should not be considered limiting of the scope of the disclosure. In the drawings, like reference numerals represent like elements between the drawings.

[0013] Specific embodiments will now be described to provide a general understanding of the principles of the structure, function, manufacture, and use of the methods, systems, and devices disclosed herein. One or more examples of these embodiments are illustrated in the accompanying drawings. Those skilled in the art will understand that the methods, systems, and devices specifically described herein and illustrated in the accompanying drawings are non-limiting embodiments. Features illustrated or described in connection with one embodiment may be combined with features of other embodiments. Such modifications and variations are intended to be within the scope of the present disclosure.

[0014] As an initial matter, a clear explanation of the subject matter of this disclosure requires the selection of specific terminology when referring to and describing related machine components. Wherever possible, common industry terminology is used and employed consistent with its accepted meaning. Unless otherwise indicated, such terminology should be given a broad interpretation consistent with the context of this application and the scope of the appended claims. Those skilled in the art will understand that in many cases, a particular component may be referred to using several different or overlapping terms. What may be described herein as a single component may, including in other contexts, be referenced as consisting of multiple components. Alternatively, what may be described herein as comprising multiple components may be referenced elsewhere as a single component.

[0015] In addition, certain descriptive terms may be used regularly in this specification, as explained below: The terms "first," "second," and "third" may be used interchangeably to distinguish one component from another, and are not intended to denote the location or importance of the individual components.

[0016] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the disclosure. As used herein, the singular forms "a," "an," and "the" are intended to include the plural forms unless the context clearly dictates otherwise. It will be further understood that the terms "comprises" and / or "comprising," when used herein, specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not exclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof. "Optionally present" or "optionally" means that the subsequently described event or circumstance may or may not occur, or that the subsequently described component or element may or may not be present, and that the description includes cases where the event occurs or the component is present and cases where the event does not occur or the component is not present.

[0017] When an element or layer is referred to as "on," "engaged," "connected," or "coupled" to another element or layer, it may be directly on, engaged, connected, or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as "directly on," "directly engaged," "directly connected," or "directly coupled" to another element or layer, there may not be intervening elements or layers. Other words used to describe relationships between elements should be interpreted similarly (e.g., "directly between" as opposed to "between," "directly adjacent" as opposed to "adjacent," etc.). As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items.

[0018] As noted above, the present disclosure provides setters, setter arrays, setter systems for investment casting cores, and methods of using the same. In particular, the present disclosure generally relates to setters, setter arrays, and setter systems for heat treating investment casting cores, and methods of using the setters, setter arrays, or setter systems to support investment casting cores during heat treating.

[0019] As mentioned above, in the investment casting field, setters or setter systems having a complementary profile to the investment casting core are typically used to minimize distortion that may occur during heat treatment of the investment casting core. In many situations, investment casting cores are customized with very tight geometric tolerances. Therefore, the corresponding setters or setter systems also require very tight geometric tolerances, similar to the investment casting cores they support. This presents challenges, including, but not limited to, extensive inventory of setters for investment casting cores with different profiles and long lead times for manufacturing setters, especially when a new setter is required for a customized investment casting core. The present disclosure has been developed to address these challenges by providing, for example, a hybrid setter including a base section and a cover section configured to mechanically couple to the base section. The cover section may include a profile for receiving the investment casting core on the cover section. The base section and the cover section may comprise different materials and may be manufactured by different processes. The disclosed hybrid setters and methods of making same offer advantages over conventional setters and methods in that they meet the customizable and tight geometric tolerance requirements for investment casting applications while minimizing the burden of extensive setter inventory and long lead times.

[0020] Referring to FIG. 1A, an exploded perspective view of setter 100 is shown. FIG. 1B is an exploded side view of setter 100. Setter 100 includes a base section 102 and a cover section 104 configured to mechanically couple to base section 102, as described in more detail below. In embodiments, cover section 104 is configured to mechanically couple to base section 102 without the use of mortar. In some embodiments, cover section 104 is configured to mechanically couple to base section 102 with the additional use of mortar. Cover section 104 includes a contour for receiving an investment casting core 108 (FIG. 1C) thereon.

[0021] In some embodiments, the base section 102 and the cover section 104 of the setter 100 may comprise the same material. In certain embodiments, the setter 100 is a hybrid setter comprising two materials that may be different. The base section 102 may comprise a first material, and the cover section 104 may comprise a second material that is different from the first material. In embodiments, the second material may be the same material as the material of the investment casting core 108 disposed on the cover section 104. Matching the second material to the material of the investment casting core provides the advantage of minimizing distortion that may occur during heat treatment of the investment casting core.

[0022] In embodiments, the first material may comprise a ceramic material, including, but not limited to, cordierite, fire clay, ball clay, tile clay, flint clay, or any combination thereof. The second material may comprise a ceramic material, including, but not limited to, alumina, mullite, silica, or zirconia, or any combination thereof. The first and second materials may be selected so that the setter 100 can withstand a temperature range of 1500°F (approximately 816°C) to 2500°F (approximately 1371°C) during heat treatment of the investment casting core 108.

[0023] In embodiments, the first material is configured to have a first porosity in the range of about 5-45 vol%, or about 10-40 vol%, or about 15-35 vol%, or about 10-35 vol%, or about 10-25 vol%, based on the total volume of the base section 102. The second material is configured to have a second porosity in the range of about 1-5 vol%, or about 2-4 vol%, based on the total volume of the cover section 104. The first and second porosities may be measured using a calibrated scale according to ASTM (American Society for Testing and Materials) standards, such as the ASTM Standard Test Method for Apparent Porosity. The first and second porosities are configured to provide thermal stability to the setter, setter array, or setter system of the present disclosure.

[0024] 1C is an exploded side view of the setter 100 with an investment casting core 108 positioned on the setter 100. In an embodiment, the cover section 104 includes an upper contour 110 that substantially mates with a lower surface 112 of the investment casting core 108 received on the cover section 104.

[0025] In some embodiments, the contour of the cover section 104 further includes a lower contour 114 that substantially mates with an upper contour 116 of the base section 102 .

[0026] It should be understood that the setters shown in Figures 1A-1C and described herein are intended to be generic representations of various setter embodiments disclosed in this disclosure and are not limited to the specific configurations, sizes, and shapes as shown. Aspects and features described with respect to Figures 1A-1C can be applied to and / or combined with features of other embodiments described throughout this disclosure. For example, the description of Figures 1A-1C, including features of the base section and cover section and the matching of the upper contour of the cover section with the lower surface of the investment casting core, can be applied to setters, setter arrays, and setter systems having various sizes / shapes / configurations as disclosed in embodiments throughout this disclosure.

[0027] Referring to FIG. 2A , an exploded perspective view of a setter 200 is presented. The setter 200 includes a base section 202 and a cover section 204 configured to mechanically couple to the base section 202. The cover section 204 includes a contour for receiving an investment casting core (not shown) thereon. In an embodiment, the contour of the cover section 204 includes an upper contour 210 that substantially mates with the underside of an investment casting core received thereon. It should be understood that the configurations of the upper contour 210 shown in other figures throughout this specification and disclosure (having similar reference numbers, such as 310, 410, etc.) are non-limiting examples. The upper contour 210 may have other shapes or configurations. For example, similar to the embodiment shown in FIG. 1C , the upper contour 210 of the cover section 204 may have a customized size and shape such that the upper contour 210 substantially mates with a portion, e.g., a lower surface portion, of an investment casting core received thereon. In certain embodiments, the cover section may be 3D printed to provide a customized shape or configuration such that the upper profile substantially mates with the underside of an investment casting core received on the upper profile.

[0028] 2A , the contour of the cover section 204 further includes a lower contour 214 that substantially mates with an upper contour 215 of the base section 202. In embodiments, the lower contour 214 of the cover section 204 may include a first sidewall extension 222 and a second sidewall extension 224 that extend toward the base section 202 (e.g., extending generally perpendicularly outward from the cover section 204 toward the base section 202), with the second sidewall extension 224 abutting the first sidewall extension 222. In embodiments, the first and second sidewall extensions 222, 224 may form a generally right angle (i.e., 90 degrees). The upper contour 215 of the base section 202 may include a third sidewall extension 218 and a fourth sidewall extension 220 that extend toward the cover section 204 (e.g., extending generally perpendicularly outward from the bottom surface of the base section 202 toward the cover section 204), the third sidewall extension 218 and the fourth sidewall extension 220 having opposite and complementary contours to the first sidewall extension 222 and the second sidewall extension 224, respectively. Thus, when the cover section 204 is received within or assembled to the base section 202, the sidewall extensions 218, 220, 222, 224 collectively form the perimeter of the setter 200, as shown in FIG. 2B . As further shown in FIG. 2B, inner surface 216a of first sidewall extension 218 and inner surface 217a of second sidewall extension 220 abut first portion 216b and second portion 217b of cover section 204, respectively.

[0029] 3A, an exploded perspective view of a setter 300 is shown. The setter 300 includes a base section 302 and a cover section 304 configured to mechanically couple to the base section 302. The cover section 304 includes a contour for receiving an investment casting core (not shown) thereon. In an embodiment, the contour of the cover section 304 includes an upper contour 310 that substantially mates with a portion, e.g., a lower surface, of the investment casting core received thereon, and a lower contour that substantially mates with the upper contour of the base section 302. In embodiments, the lower contour of the cover section 304 may include a first sidewall extension 318 that extends (e.g., extends generally perpendicularly outwardly toward the base section 302) and a second sidewall extension 320 that is opposite the first sidewall extension 318. The upper contour of the base section 302 may include a circumferential boundary that extends (e.g., extends generally perpendicularly outwardly) from the bottom surface of the base section 302 toward the cover section 304, defining the peripheral boundary of the base section 302. The cover section 304 may include a peripheral sidewall extension 322 that is sized and shaped to receive and enclose the first and second sidewall extensions 318, 320 within the peripheral sidewall extension 322. As shown in FIG. 3B , when the cover section 304 is received within or assembled to the base section 302, the outer surface of each of the first and second sidewall extensions 318, 320 abuts the inner surfaces of the first and second portions, respectively, of the peripheral sidewall extension 322.

[0030] 4A is an exploded perspective view of a setter 400. The setter 400 includes a base section 402 and a cover section 404 configured to mechanically couple to the base section 402. In an embodiment, the cover section 404 includes a contour for receiving an investment casting core (not shown) thereon. The contour of the cover section 404 may include an upper contour 410 that substantially mates with a portion, e.g., a lower surface, of the investment casting core received thereon, and a lower contour that substantially mates with the upper contour of the base section 402. In an embodiment, the upper contour of the base section 402 may include a semi-cylindrical portion 424 that extends (e.g., extends generally perpendicularly outward) from a bottom surface of the base section 402 toward the cover section 404.

[0031] 4B, in certain embodiments, the inner surface of cover section 404 includes at least a portion having a contour that matches semi-cylindrical portion 424. Semi-cylindrical portion 424 is configured such that at least a portion of semi-cylindrical portion 424 abuts at least a portion of inner surface 414 of cover section 404 when cover section 404 is received within base section 402 (FIG. 4C). The lower contour of cover section 404 may include a peripheral sidewall 426, where at least a portion of the outer surface of semi-cylindrical portion 424 abuts at least a portion of the inner surface of peripheral sidewall 426.

[0032] The base section 402 may further include a lip 428 that surrounds the semi-cylindrical portion 424. Figure 4C provides a top perspective view of the setter 400 showing the cover section 404 received within the base section 402, with the periphery of the cover section 404 positioned on and abutting the lip 428.

[0033] 5A is an exploded perspective view of a setter 500. The setter 500 includes a base section 502 and a cover section 504 configured to mechanically couple to the base section 502. In an embodiment, the cover section 504 includes a contour for receiving an investment casting core (not shown) thereon. The contour of the cover section 504 may include an upper contour 510 that substantially mates with a portion, e.g., a lower surface, of the investment casting core received thereon, and a lower contour that substantially mates with the upper contour of the base section 502. In an embodiment, the upper contour of the base section 502 may include a semi-cylindrical portion 524 that extends (e.g., extends generally perpendicularly outward) from a bottom surface of the base section 502 toward the cover section 504.

[0034] 5B, in certain embodiments, inner surface 514 of cover section 504 includes at least a portion having a contour that matches semi-cylindrical portion 524. Semi-cylindrical portion 524 is configured such that at least a portion of semi-cylindrical portion 524 abuts at least a portion of inner surface 514 of cover section 504 when cover section 504 is received within base section 502 (FIG. 5C). The lower contour of cover section 504 may include a peripheral wall 526, where at least a portion of the outer surface of semi-cylindrical portion 524 abuts at least a portion of the inner surface of peripheral wall 526.

[0035] Base section 502 may further include a lip 528 surrounding semi-cylindrical portion 524 and a protrusion 530 disposed on and extending upwardly from lip 528. In some embodiments, protrusion 530 may have a cylindrical profile. The lower profile of cover section 504 may further include a recess 532 sized and shaped to receive at least a portion of protrusion 530.

[0036] FIG. 5C provides a top perspective view of setter 500 showing cover section 504 received within base section 502, with peripheral edge 538 of cover section 504 positioned over and abutting lip 528, and at least a portion of protrusion 530 received within recess 532 and abutting a portion of peripheral wall 526.

[0037] 6A is an exploded perspective view of a setter 600. The setter 600 includes a base section 602 and a cover section 604 configured to mechanically couple to the base section 602. In an embodiment, the cover section 604 includes a contour for receiving an investment casting core (not shown) thereon. The contour of the cover section 604 may include an upper contour 610 that substantially mates with a portion of the investment casting core received thereon, such as a lower surface of the investment casting core, and a lower contour that substantially mates with the upper contour of the base section 602. In an embodiment, the base section 602 may include a peripheral groove 634. The peripheral groove 634 is configured to be positioned between a central portion 636 of the base section 602 and a lip 628 that surrounds the central portion 636. In certain embodiments, the peripheral groove 634 is configured to receive a peripheral edge 638 of the cover section 604 therein.

[0038] FIG. 6B provides a top perspective view of the setter 600 showing the cover section 604 received within the base section 602, with the peripheral edge 638 of the cover section 604 received within the peripheral groove 634 and abutting the lip 628.

[0039] 7A is an exploded perspective view of a setter 700. The setter 700 includes a base section 702 and a cover section 704 configured to mechanically couple to the base section 702. In an embodiment, the cover section 704 includes a contour for receiving an investment casting core (not shown) thereon. The contour of the cover section 704 may include an upper contour 710 that substantially mates with a portion of the investment casting core received thereon, such as a lower surface of the investment casting core, and a lower contour 714 that substantially mates with the upper contour of the base section 702. In an embodiment, the base section 702 may include a central portion 736 that extends upward from a bottom surface of the base section 702 and a lip 728 that surrounds the central portion 736. When cover section 704 is received within base section 702 , the inner peripheral surface of lower contour 714 of cover section 704 abuts the outer peripheral surface of central portion 736 .

[0040] FIG. 7B provides a top perspective view of the setter 700 showing the cover section 704 received within the base section 702 with the peripheral edge 738 of the cover section 704 positioned on and abutting the lip 728 .

[0041] 8A is a perspective view of a setter 800. The setter 800 includes a base section 802 and a cover section 804 configured to mechanically couple to the base section 802. In an embodiment, the cover section 804 includes a contour for receiving an investment casting core (not shown) thereon. The contour of the cover section 804 may include an upper contour 810 that substantially mates with a portion of the investment casting core received thereon, such as a lower surface of the investment casting core, and a lower contour 814 that substantially mates with the upper contour of the base section 802. In an embodiment, the cover section 804 is configured to slidably engage the base section 802.

[0042] 8B , the cover section 804 may include a first dovetail edge 840 and a second dovetail edge 842 opposite the first dovetail edge 840. The base section 802 may include a central portion 836 extending upward from a bottom surface of the base section 802 and includes a first side surface 844 and a second side surface 846 opposite the first side surface 844. In certain embodiments, each of the first and second side surfaces 844, 846 projects outward toward a respective one of the first and second dovetail edges 840, 842 and has a complementary contour to the respective one of the first and second dovetail edges 840, 842. In some embodiments, the first and second sides 844, 846 each have a beveled surface that is angled to match the angle of the beveled inner surface of each of the first and second sides 844, 846 such that the first and second sides 844, 846 abut the first and second dovetail edges 840, 842, respectively, when the cover section 804 is received within the base section 802. Such a configuration mechanically couples the cover section 804 to the base section 802.

[0043] 9A is a perspective view of a setter 900. The setter 900 includes a base section 902 and a cover section 904 configured to mechanically couple to the base section 902. In an embodiment, the cover section 904 includes a contour for receiving an investment casting core (not shown) thereon. The contour of the cover section 904 may include an upper contour 910 that substantially mates with a portion of the investment casting core received thereon, such as a lower surface of the investment casting core, and a lower contour 914 that substantially mates with the upper contour of the base section 902. In an embodiment, the cover section 904 is configured to slidably engage the base section 902.

[0044] 9A , the cover section 904 may include a first dovetail edge 940 and a second dovetail edge 942 opposite the first dovetail edge 940. The base section 902 may include a central portion 903 extending substantially perpendicularly outward from a bottom surface of the base section 902 and a lip 928 surrounding the central portion 903. The central portion 903 may include a first side surface 944 and a second side surface 946 opposite the first side surface 944. In certain embodiments, each of the first and second side surfaces 944, 946 projects outward (e.g., substantially perpendicularly) toward a respective one of the first and second dovetail edges 940, 942 and has a complementary contour to the respective one of the first and second dovetail edges 940, 942. In some embodiments, the first and second sides 944, 946 each have a beveled surface angled to match the contours of the first and second sides 944, 946, respectively, such that the first and second sides 944, 946 abut the first and second dovetail edges 940, 942, respectively, when the cover section 904 is received within the base section 902. Such a configuration mechanically couples the cover section 904 to the base section 902.

[0045] FIG. 9B provides a top perspective view of the setter 900 showing the cover section 904 received within the base section 902 with the peripheral edge 938 of the cover section 904 positioned over and abutting the lip 928 .

[0046] It should be understood that the slidable engagement between the cover and base sections of the setter as shown in the figures of this disclosure is a non-limiting example, and other slidable engagements between the cover and base sections of the setter may be used.

[0047] 10A , an exploded perspective view of a setter 1000 is shown. The setter 1000 includes a base section 1002 and a cover section 1004 configured to mechanically couple to the base section 1002. In an embodiment, the cover section 1004 includes a contour for receiving an investment casting core (not shown) thereon. The contour of the cover section 1004 may include an upper contour 1010 that substantially mates with a portion, e.g., a lower surface, of the investment casting core received thereon, and a lower contour 1014 that substantially mates with the upper contour of the base section 1002. In an embodiment, the cover section 1004 is configured to slidably lock the base section 1002.

[0048] 10A and 10B , in embodiments, the lower profile of the cover section 1004 may include a sidewall 1052 and a protrusion 1054 extending substantially perpendicularly outward from the sidewall 1052 of the cover section 1004 toward the base section 1002. The base section 1002 may include a protrusion engagement structure 1056 for receiving the protrusion 1054 of the cover section 1004 within the base section 1002. In some embodiments, the protrusion 1054 is configured to have a profile complementary to the profile of the protrusion engagement structure 1056 such that the protrusion engagement structure 1056 receives and slidably locks the protrusion 1054 within the protrusion engagement structure 1056. Such a configuration mechanically couples the cover section 1004 to the base section 1002. In certain embodiments, both the protrusion 1054 and the protrusion engagement structure 1056 have an L-shape.

[0049] In FIG. 10C, a side view of the setter 1000 is provided showing the cover section 1004 received within the base section 1002 with the protrusions 1054 fully received and positioned within the protrusion engagement structures 1056.

[0050] 11A provides an exploded perspective view of a setter 1100. The setter 1100 includes a base section 1102 and a cover section 1104 configured to mechanically couple to the base section 1102. In an embodiment, the cover section 1104 includes a contour for receiving an investment casting core (not shown) thereon. The contour of the cover section 1104 may include an upper contour 1110 that substantially mates with a portion, e.g., a lower surface, of the investment casting core received thereon, and a lower contour 1114 that substantially mates with the upper contour of the base section 1102. In an embodiment, the cover section 1104 is configured to rotatably lock the base section 1102.

[0051] 11B-11D , in embodiments, the underside 1158 of the cover section 1104 includes the locking unit 1160. For example, the underside 1158 of the lower contour 1114 of the cover section 1104 includes the locking unit 1160. The base section 1102 may include a notch 1162 that receives the locking unit 1160 and pivotally locks the locking unit 1160 of the cover section 1104 within the base section 1102. The notch 1162 may include a mechanical mating member that functions as a mechanical fastening mechanism that mates with a corresponding mating mechanism on the locking unit 1160. In embodiments, the notch 1162 may include one or more tabs 1164 on an inner surface of the notch 1162. The locking unit 1160 may include one or more slots 1166 sized to allow the one or more tabs 1164 to fit within the one or more slots 1166 when the cover section 1104 is received within the base section 1102 and rotated relative to the base section 1102 during installation. In a particular embodiment, the cutout 1162 includes multiple tabs 1164 located on opposing portions of an inner surface of the cutout 1162, and the locking unit 1160 includes multiple slots 1166 formed in opposing locations on a sidewall of the locking unit 1160, each of the multiple slots 1166 sized to allow a respective one of the multiple tabs 1164 to fit within the multiple slots 1166. In an embodiment, the cutout 1162 includes a through hole extending between the top and bottom surfaces of the base section 1102, and the one or more tabs 1164 are disposed on a peripheral inner surface of the through hole.

[0052] 12A , an exploded perspective view of a setter array 1200 for a plurality of investment casting cores is shown. The setter array 1200 includes a base section 1202 and a plurality of cover sections 1204, each configured to mechanically couple to a respective portion of the base section 1202. In an embodiment, each of the plurality of cover sections 1204 includes a contour for receiving a respective one of a plurality of investment casting cores (not shown) thereon. The contour of each cover section 1204 may include an upper contour 1210 that substantially mates with a portion, e.g., a lower surface, of the investment casting core received thereon, and a lower contour 1214 that substantially mates with the upper contour of the respective portion of the base section 1202. In an embodiment, each of the multiple investment casting cores may have a unique contour that is different from one another, and each upper contour 1210 may be individually customized to substantially mate with a corresponding contour on the lower surface of each of the multiple investment casting cores received on each upper contour 1210.

[0053] In Figure 12A, base section 1202 is depicted as a plurality of individual base sections, each configured to be mechanically coupled to a respective one of a plurality of cover sections. It should be understood that the embodiment of Figure 12A is a non-limiting example, and other configurations of base section 1202 may be used. For example, base section 1202 may be provided as a single-section component or a multi-section component, with each section of the multi-section component corresponding to one or more of the plurality of cover sections.

[0054] In some embodiments, the base section 1202 and one or more of the plurality of cover sections 1204 may comprise the same material. In certain embodiments, the setter array 1200 is a hybrid setter comprising two different materials. The base section 1202 may comprise a first material, and each of the plurality of cover sections 1204 may comprise a second material different from the first material. In embodiments, the second material is the same material as the material of a respective investment casting core disposed on a respective one of the plurality of cover sections 1204. Matching the second material to the material of the investment casting core provides the advantage of minimizing distortion that may occur during heat treatment of the plurality of investment casting cores.

[0055] In an embodiment, the first material may be a ceramic material including, but not limited to, cordierite, fire clay, ball clay, tile clay, flint clay, or any combination thereof. The second material may be a ceramic material including, but not limited to, alumina, mullite, silica, or zirconia, or any combination thereof. The second ceramic material may be different from the first ceramic material. The first and second materials may be selected so that the setter array 1200 can withstand a temperature range of 1500°F (approximately 816°C) to 2500°F (approximately 1371°C) during heat treatment of an investment casting core placed on the setter array 1200.

[0056] In embodiments, the first material is configured to have a first porosity in the range of about 5-45 vol%, or about 10-40 vol%, or about 15-35 vol%, or about 10-35 vol%, or about 10-25 vol%, based on the total volume of the base section 1202. The second material of each of the plurality of cover sections 1204 is configured to have a second porosity in the range of about 1-5 vol%, or about 2-4 vol%, based on the total volume of each of the plurality of cover sections 1204. The first porosity and the second porosity may be measured using a calibrated scale according to ASTM (American Society for Testing and Materials) standards, such as the ASTM Standard Test Method for Apparent Porosity. The first porosity and the second porosity are selected to provide additional thermal stability to the setter or setter system of the present disclosure.

[0057] 12A and 12B , in embodiments, the base section 1202 may include a plurality of protrusions 1270 extending substantially perpendicularly outward from a bottom surface of the base section 1202. Each of the plurality of cover sections 1204 may include a protrusion engagement structure 1272 for receiving a respective one of the plurality of protrusions 1270 of the base section 1202 within each of the plurality of cover sections 1204. The protrusion engagement structure 1272 and each one of the plurality of protrusions 1270 have complementary contours. In embodiments, each protrusion engagement structure 1272 is sized to fit and abut a corresponding one of the plurality of protrusions 1270. Such a configuration mechanically couples each of the plurality of cover sections 1204 to a corresponding portion of the base section 1202.

[0058] It should be understood that the setter array 1200 shown herein is a non-limiting example. For example, the configuration of each of the setters 100-1100 as described herein may be incorporated with other now known or later developed mechanical coupling mechanisms between the cover section and base section of the present disclosure and remain within the scope of the setters and setter arrays of the present disclosure.

[0059] In an embodiment, each of the plurality of cover sections 1204 is configured to slidably lock to a respective portion of the base section 1202. In an embodiment, each of the plurality of cover sections 1204 is configured to rotatably lock to a respective portion of the base section 1202.

[0060] FIG. 12C provides a perspective view of the setter array 1200 showing a plurality of cover sections 1204 received within the base section 1202, with each of the plurality of protrusions 1270 fully received and positioned within a corresponding one of the plurality of protrusion engagement structures 1272.

[0061] 13A is a perspective view of a setter array 1300. The setter array 1300 includes a base section 1302 and a plurality of cover sections 1304, each configured to mechanically couple to a respective portion of the base section 1302. In an embodiment, each of the plurality of cover sections 1304 includes a contour for receiving a respective one of a plurality of investment casting cores (not shown) on each of the plurality of cover sections 1304. The contour of each of the plurality of cover sections 1304 may include an upper contour 1310 that substantially mates with a portion, e.g., a lower surface, of the investment casting core received on the upper contour 1310, and a lower contour 1314 that substantially mates with the upper contour of the respective portion of the base section 1302.

[0062] In some embodiments, the base section 1302 and one or more of the plurality of cover sections 1304 may comprise the same material. In certain embodiments, the setter array 1300 is a hybrid setter comprising two different materials. The base section 1302 may comprise a first material, and each of the plurality of cover sections 1304 may comprise a second material different from the first material. In embodiments, the second material is the same material as the material of a respective investment casting core disposed on a respective one of the plurality of cover sections 1304. Matching the second material to the material of the investment casting core provides the advantage of minimizing distortion that may occur during heat treatment of the plurality of investment casting cores.

[0063] In an embodiment, the first material may be a ceramic material including, but not limited to, cordierite, fire clay, ball clay, tile clay, flint clay, or any combination thereof. The second material may be a ceramic material including, but not limited to, alumina, mullite, silica, or zirconia, or any combination thereof. The first and second materials may be selected so that the setter array 1300 can withstand a temperature range of 1500°F (approximately 816°C) to 2500°F (approximately 1371°C) during heat treatment of an investment casting core placed on the setter array 1300.

[0064] In embodiments, the first material is configured to have a first porosity in the range of about 5-45 vol%, or about 10-40 vol%, or about 15-35 vol%, or about 10-35 vol%, or about 10-25 vol%, based on the total volume of the base section 1302. The second material of each of the plurality of cover sections 1304 is configured to have a second porosity in the range of about 1-5 vol%, or about 2-4 vol%, based on the total volume of each of the plurality of cover sections 1304. The first porosity and second porosity may be measured using a calibrated scale according to ASTM (American Society for Testing and Materials) standards, such as the ASTM Standard Test Method for Apparent Porosity. The first porosity and second porosity are selected to provide additional thermal stability to the setter or setter system of the present disclosure.

[0065] In FIG. 13B, a side view of the setter array 1300 is provided showing the cover section 1304 received within the base section 1302, with the protrusions 1374 fully received and positioned within the protrusion engagement structures.

[0066] 13B , in certain embodiments, the protrusion engagement structure may be a T-shaped slot 1376 positioned on the bottom surface of the base section 1302 and extending along the longitudinal axis of the base section 1302. Each of the plurality of cover sections 1304 may include a protrusion 1374 having an upper surface configured to abut a portion of the lower surface of the T-shaped slot 1376. When the plurality of cover sections 1304 are received within the base section 1302, the protrusion 1374 is fully received and positioned within the T-shaped slot 1376. Such a configuration mechanically couples the cover sections 1304 to the base section 1302. It should be understood that the setter array 1300 as shown herein is a non-limiting example. For example, the base section 1302 may be provided as a single-section component or a multi-section component, with each section of the multi-section component corresponding to one or more of the plurality of cover sections. Additionally, the configuration of each of the setters 100-1100 as disclosed may be incorporated into the setter arrays described herein along with other now known or later developed mechanical coupling mechanisms between the cover sections and base sections of the present disclosure, and are within the scope of the present disclosure. For example, in embodiments in which the base section includes multiple portions, each corresponding to one or more of the multiple cover sections, one or more of the respective portions of the base section may further include a central portion extending from the base section toward the cover section and a lip surrounding the central portion.

[0067] FIG. 14 illustrates an exploded side view of an alternative embodiment of a setter system with an investment casting core disposed therein. According to an embodiment of the present disclosure, the setter system includes a first setter 1400 and a second setter 1420, with an investment casting core 1408 sandwiched between the first setter 1400 and the second setter 1420. The first setter 1400 illustrated in FIG. 14 is similar to the setter 100 described in FIGS. 1A-1C and will not be described in detail here. However, it should be understood that the first setter 1400 may include the embodiments described with respect to each of the setters 100-1100 and throughout this disclosure. In a specific embodiment, the first setter 1400 includes a first cover section 1404 and a base section 1402. The contour of the cover section 1404 may include an upper contour 1410 that substantially mates with a first portion received on the upper contour 1410, e.g., a lower surface 1412 of the investment casting core 1408. In an embodiment, the second setter 1420 includes a second cover section 1424 and a cap section 1422. The second cover section 1424 is configured to be positioned over the investment casting core 1408, and the cap section 1422 is configured to couple to the second cover section 1424. In an embodiment, the second cover section 1424 includes a contour for positioning the second cover section 1424 over the investment casting core 1408. The contour of the second cover section 1424 may include a lower contour that substantially mates with a second portion of the investment casting core 1408, e.g., a top surface 1418 of the investment casting core 1408. The contour of the second cover section 1424 may further include an upper contour that substantially mates with a lower contour of the cap section 1422. It should be understood that the embodiments and materials of the second setter 1420 and fabrication methods may be similar to the first setter 1400, including but not limited to the examples described throughout this disclosure.

[0068] As shown in FIG. 15, in an alternative embodiment of a setter system including a first setter 1500 and a second setter 1520 similar to those described in the embodiment of FIG. 14, when the second setter 1520 is in place, a second cover section 1524 may completely cover the investment casting core sandwiched between the first setter 1500 and the second setter 1520, and a cap section 1522 is coupled to the second cover section 1524 according to an embodiment of the present disclosure.

[0069] FIG. 16 is a flow diagram of a method for supporting an investment casting core using a setter of the present disclosure during heat treatment. The method may include providing a base section S1602, mechanically coupling a cover section to the base section S1604, the cover section including a contour for receiving the investment casting core on the cover section, and positioning the investment casting core on the cover section S1606 such that a lower surface of the investment casting core substantially mates with a portion of the contour of the cover section that receives the investment casting core on the cover section. The method may optionally include positioning a second cover section (e.g., second cover section 1424 of FIG. 14 ) on the investment casting core S1608. An additional optional step (e.g., step S1610) may include mechanically coupling a cap section 1422 of a second setter 1420 to the second cover section 1424. In certain embodiments, one or both of steps S1604 and S1610 may be performed without the use of mortar. In embodiments, one or both of steps S1604 and S1610 may include the additional use of mortar. The method may further include heat treating the investment casting core positioned on the setter. In embodiments, the method further includes heat treating the investment casting core positioned on the setter to a temperature range of 1500°F (approximately 816°C) to 2500°F (approximately 1371°C).

[0070] Various non-limiting configurations of setters, setter systems, setter arrays, and investment casting cores, such as those described in Figures 1-15 and throughout this disclosure, may be used in the present methods. In an embodiment, the investment casting core may be a ceramic core.

[0071] The base section and cover section may be manufactured differently using various methods and materials. For example, lower-cost materials and manufacturing methods may be selected when manufacturing the base section. The present disclosure provides embodiments in which the primary function of the base section is to provide stability for the cover section and is not configured to directly contact the investment casting core during heat treatment. Therefore, the geometric and dimensional tolerances of the base section are not as tightly controlled as those of the cover section, and different materials may be used for the base and cover sections, thereby enabling shorter lead times while meeting the setter design specifications. Low-cost materials for the base section may include, but are not limited to, cordierite and clay (e.g., fire clay, ball clay, tile clay, flint clay), or any combination thereof.

[0072] The manufacturing method for the base section depends on the design of the setter. For example, in certain embodiments, a continuous process such as an extrusion process may be used. In more complex embodiments, methods that allow for the incorporation of additional design complexities, such as a dry pressing process, may be used.

[0073] The cover section may be in direct contact with the customized investment casting core, which places higher requirements on tolerances (geometry and dimensions, including surface roughness) and material selection. In embodiments, the material of the cover section is the same as the material of the customized investment casting core. Typical materials for the cover section may include, but are not limited to, alumina, mullite, silica, and zirconia, or any combination thereof.

[0074] To manufacture cover sections with highly complex designs and achieve the required tolerances, additive manufacturing methods, such as stereolithography additive manufacturing, may be used, which provide complex designs with tight tolerances and low surface roughness.

[0075] In an embodiment, the method may further include forming a base section having a first material and forming a cover section having a second material different from the first material. The method may also include selecting the second material to be the same as a material of the investment casting core. In an embodiment, the first material includes a first ceramic material and the second material includes a second ceramic material different from the first ceramic material. The first and second materials may be selected so that the setter array 1300 can withstand a temperature range of 1500°F (approximately 816°C) to 2500°F (approximately 1371°C) during heat treatment of the investment casting core disposed on the setter array 1300.

[0076] In embodiments, the method may further include controlling the first porosity of the first material within a range of about 5-45 vol%, or about 10-40 vol%, or about 15-35 vol%, or about 10-35 vol%, or about 10-25 vol%, based on the total volume of the base section. The method may further include controlling the second porosity of the second material within a range of about 1-5 vol%, or about 2-4 vol%, based on the total volume of the cover section. The first porosity and the second porosity may be measured using a calibrated scale according to ASTM (American Society for Testing and Materials) standards, such as the ASTM Standard Test Method for Apparent Porosity. It should be understood that the methods disclosed in this disclosure are non-limiting examples. Other now-known or later-developed methods for manufacturing the cover and base sections of the present disclosure may also be used and are within the scope of this disclosure.

[0077] The foregoing drawings illustrate some of the processes associated in accordance with some embodiments of the present disclosure. In this regard, each drawing or block within the flow diagrams of the drawings represents a process associated with the described method embodiment. It should also be noted that in some alternative implementations, the actions depicted in the drawings or blocks may occur out of the order depicted in the drawings, or may actually be performed substantially simultaneously or in reverse order, depending, for example, on the actions involved. Those skilled in the art will also recognize that additional blocks describing a process may be added.

[0078] The disclosed method provides a hybrid setter in which the base section and cover section may comprise different materials and be manufactured by different processes, thereby satisfying the need to quickly provide setters for customized investment casting cores, resulting in reduced lead times and maintaining geometric tolerances of the setter.

[0079] As used herein throughout the specification and claims, approximation language may be applied to modify any quantitative expression that can vary within acceptable limits without resulting in a change in the basic function involved. Thus, values ​​modified with one or more terms, such as "about," "approximately," and "substantially," are not limited to the exact value specified. In at least some instances, approximation language may correspond to the precision of the instrument used to measure the value. Here, and throughout the specification and claims, range limitations may be combined and / or substituted, and such ranges, where specified, include all subranges contained therein unless the context or language dictates otherwise. When applied to a particular value in a range, "about" applies to both endpoints and may indicate + / - 10% of the stated value, unless specifically dependent on the precision of the instrument used to measure the value.

[0080] The corresponding structure, material, acts, and equivalents of all means-plus-function or step-plus-function elements in the following claims are intended to include any structure, material, or acts for performing the function as specifically claimed in combination with other claimed elements. The description of the present disclosure has been presented for purposes of illustration and description, but is not intended to be exhaustive or to limit the disclosure to the form disclosed. Many modifications and variations will be apparent to those skilled in the art without departing from the scope and spirit of the disclosure. The embodiments were chosen and described to best explain the principles and practical applications of the disclosure and to enable those skilled in the art to understand the disclosure for various embodiments with various modifications suited to the particular applications contemplated.

Claims

1. 1. A setter for investment casting cores, said setter comprising: a base section; a cover section configured to mechanically couple to the base section, the cover section having a contour for receiving an investment casting thereon. Setta.

2. The setter of claim 1 , wherein the base section comprises a first material and the cover section comprises a second material different from the first material.

3. The setter of claim 2 , wherein the second material is the same as the material of the investment casting core.

4. The setter of claim 2 , wherein the first material comprises a first ceramic material and the second material comprises a second ceramic material different from the first ceramic material.

5. 3. The setter of claim 2, wherein the first material has a first porosity, the second material has a second porosity, the first porosity being in the range of 5 to 45 vol% based on a total volume of the base section, and the second porosity being in the range of 1 to 5 vol% based on a total volume of the cover section.

6. 3. The setter of claim 2, wherein the first and second materials are selected to withstand a temperature range of 1500°F (about 816°C) to 2500°F (about 1371°C) during heat treatment of the investment casting core.

7. The setter of claim 1 , wherein the cover section is configured to mechanically couple to the base section without the use of mortar.

8. The setter of claim 1 , wherein the contour of the cover section includes an upper contour that substantially mates with a lower surface of the investment casting core received on the cover section.

9. The setter of claim 1 , wherein the contour of the cover section further includes a lower contour that substantially mates with an upper contour of the base section.

10. 8. The setter of claim 7, wherein a lower contour of the cover section includes first and second sidewall extensions extending toward the base section, the second sidewall extension abutting the first sidewall extension, and an upper contour of the base section includes third and fourth sidewall extensions extending toward the cover section, the third and fourth sidewall extensions facing the first and second sidewall extensions, respectively, and having complementary contours to the first and second sidewall extensions.

11. The setter of claim 8 , wherein the first and second sidewall extensions form a substantially right angle.

12. 8. The setter of claim 7, wherein a lower contour of the cover section includes first and second sidewall extensions extending toward the base section, and an upper contour of the base section includes a peripheral sidewall extension for receiving and enclosing the first and second sidewall extensions within the peripheral sidewall extension.

13. 8. The setter of claim 7, wherein the upper profile of the base section includes a semi-cylindrical portion extending from a bottom surface of the base section toward the cover section.

14. 12. The setter of claim 11, wherein at least a portion of the semi-cylindrical portion abuts a portion of the inner surface of the cover section.

15. The setter of claim 11 , wherein the base section further includes a lip surrounding the semi-cylindrical portion.

16. The setter of claim 13 , wherein the base section further includes a protrusion disposed on a lip and extending from the lip toward the cover section.

17. 15. The setter of claim 14, wherein the lower contour of the cover section further includes a recess sized and shaped to receive at least a portion of the protrusion.

18. 8. The setter of claim 7, wherein the base section further includes a peripheral groove for receiving a peripheral edge of the cover section therein.

19. 8. The setter of claim 7, wherein the base section further includes a central portion extending from a bottom surface of the base section toward the cover section, and a lip surrounding the central portion.

20. 20. The setter of claim 18, wherein the lower contour of the cover section has a peripheral inner surface configured to abut the peripheral outer surface of the central portion.

21. The setter of claim 1 , wherein the cover section is configured to slidably engage the base section.

22. 21. The setter of claim 20, wherein the cover section includes a first dovetail edge and a second dovetail edge opposite the first dovetail edge.

23. 22. The setter of claim 21, wherein the base section includes a central portion extending from a bottom surface of the base section toward the cover section, the central portion having a first side and a second side opposite the first side, each of the first and second sides projecting outward toward a respective one of a first dovetail edge and a second dovetail edge and having a complementary contour to the respective one of the first dovetail edge and the second dovetail edge.

24. The setter of claim 1 , wherein the cover section further includes a protrusion extending from a sidewall of the cover section toward the base section.

25. 24. The setter of claim 23, wherein the base section further includes a projection engagement structure configured to receive and slidably lock a projection of the cover section.

26. The setter of claim 1 , wherein the cover section is configured to rotatably lock the base section.

27. 26. The setter of claim 25, wherein a rear surface of the cover section includes a locking unit, and the base section includes a notch configured to receive the locking unit and rotatably lock the locking unit of the cover section within the notch.

28. 27. The setter of claim 26, wherein the cutout includes one or more tabs disposed on an inner surface of the cutout, and the locking unit includes one or more slots sized to allow the one or more tabs to fit within the one or more slots.

29. 31. The setter of claim 30, wherein the cutout includes a through hole extending between the upper and lower surfaces of the base section, and wherein one or more tabs are disposed on a peripheral inner surface of the through hole.

30. 1. A setter array for a plurality of investment casting cores, said setter array comprising: a base section; a plurality of cover sections, each configured to mechanically couple to a respective portion of the base section, the plurality of cover sections having a contour for receiving a respective one of the plurality of investment casting cores thereon; Setter array.

31. 30. The setter array of claim 28, wherein the base section comprises a first material and one or more of the plurality of cover sections comprises a second material different from the first material.

32. 31. The setter array of claim 30, wherein the second material is the same as the material of each respective one of the plurality of investment casting cores.

33. 33. The setter array of claim 32, wherein each of the plurality of cover sections includes an upper contour that substantially mates with a surface of the plurality of investment casting cores received on each of the plurality of cover sections.

34. 33. The setter array of claim 32, wherein each of the plurality of cover sections includes a lower contour that substantially mates with a respective portion of an upper contour of the base section.

35. 33. The setter array of claim 32, wherein the base section includes a T-shaped slot positioned on a bottom surface of the base section and extending along a longitudinal axis of the base section for mechanically coupling the plurality of cover sections.

36. 45. The setter array of claim 44, wherein each of the plurality of cover sections includes a protrusion having an upper surface configured to abut a portion of a surface of the T-shaped slot.

37. 33. The setter array of claim 32, wherein one or more of the respective portions of the base section further includes a central portion extending from the base section toward the cover section and a lip surrounding the central portion.

38. 1. A method for supporting an investment casting core using a setter during heat treatment, the method comprising: providing a base section; mechanically coupling a cover section to the base section, the cover section including a contour on the cover section for receiving the investment casting core; positioning the investment casting core over the cover section such that a lower surface of the investment casting core substantially mates with a portion of the contour of the cover section that receives the investment casting core on the cover section; A method comprising:

39. forming a base section having a first material; forming a cover section having a second material different from the first material; 47. The method of claim 46, further comprising:

40. 48. The method of claim 47, further comprising selecting the second material to be the same as the material of the investment casting core.

41. 48. The method of claim 47, wherein the first material comprises a first ceramic material and the second material comprises a second ceramic material different from the first ceramic material.

42. 47. The method of claim 46, wherein providing a base section comprises forming the base section by one of a continuous process, an extrusion process, and a dry pressing process.

43. 47. The method of claim 46, further comprising forming the cover section by an additive manufacturing process or preferably a stereolithography additive manufacturing process.

44. 47. The method of claim 46, further comprising heat treating the investment casting core positioned on the setter.

45. 57. The method of claim 56, further comprising heat treating the investment casting core positioned on the setter to a temperature range of 1500°F (about 816°C) to 2500°F (about 1371°C).

46. 47. The method of claim 46, further comprising positioning the second cover section on the investment casting core such that a top surface of the investment casting core substantially mates with a portion of the contour of the second cover section.

47. 59. The method of claim 58, further comprising coupling the cap section to the second cover section.

48. The method of claim 1 , wherein mechanically joining the cover section to the base section is performed without the use of mortar.

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