Additive Casting of Metallic Parts Using Layered Mold Segmentation
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Solution Overview
Problem
Current casting methods, including traditional and modern techniques, are expensive, time-consuming, and inflexible, with three-dimensional printing of metal objects often resulting in inferior mechanical properties and requiring additional gravitational casting stages.
Innovation Solution
The method involves depositing mold layers and pouring liquid substances in a layered manner, allowing for the formation of casted layers that can be joined and treated using various techniques, enabling the creation of complex parts with precise control over chemical composition and microstructure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional casting methods are used, then reliable part production is achieved, but production time and cost increase significantly
Solution Approach 1:
The mold is divided into multiple layers that are deposited sequentially, with liquid metal poured between layers. This segmentation allows the mold to be built up layer by layer, eliminating the need for lengthy traditional mold fabrication while maintaining casting reliability.
Solution Approach 2:
The mold layers are prepared and positioned before the liquid metal is poured. By pre-assembling the mold structure layer by layer, the actual casting process becomes rapid and efficient, significantly reducing total production time.
2Reliability
If traditional casting methods are used, then reliable part production is achieved, but manufacturing cost increases
Solution Approach 1:
The mold is divided into multiple layers that are deposited sequentially, with liquid metal poured between layers. This segmentation allows the mold to be built up layer by layer, eliminating the need for lengthy traditional mold fabrication while maintaining casting reliability.
Solution Approach 2:
The support structure is removed after the casting is complete, and the mold layers are discarded after use. This approach eliminates the need for expensive, time-consuming mold fabrication and allows for rapid reuse of the deposition system.
3Adaptability or versatility
If three-dimensional printing of metal objects is used, then design flexibility is improved, but mechanical properties deteriorate
Solution Approach 1:
The mold is divided into multiple layers that are deposited sequentially, with liquid metal poured between layers. This segmentation allows the mold to be built up layer by layer, eliminating the need for lengthy traditional mold fabrication while maintaining casting reliability.
Solution Approach 2:
The process uses phase transition of the liquid metal from liquid to solid as it is poured into the mold layers. This phase change ensures proper solidification and mechanical properties, unlike direct 3D printing of metal which lacks this controlled phase transition.
4Adaptability or versatility
If three-dimensional printing of metal objects is used, then design flexibility is improved, but additional gravitational casting stages are required
Solution Approach 1:
The mold fabrication and casting processes are merged into a single integrated system. The same deposition system that creates the mold layers also facilitates the pouring and solidification of liquid metal, eliminating the need for separate gravitational casting stages.
Solution Approach 2:
The mold is divided into multiple layers that are deposited sequentially, with liquid metal poured between layers. This segmentation allows the mold to be built up layer by layer, eliminating the need for lengthy traditional mold fabrication while maintaining casting reliability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach allows for the efficient production of high-quality casted parts with improved mechanical properties and flexibility, reducing production time and costs while maintaining precision in design changes.
Implementation Method 1
pouring liquid substance into the first portion of the mold to form a first casted layer; solidifying at least a portion of the first casted layer
Data Source
AI summary
A method and an apparatus for additive casting of parts is disclosed. The method may include: depositing, on a build table, a first portion of a mold, such that, the depositing may be performed layer by layer; pouring liquid substance into the first portion of the mold to form a first casted layer; solidifying at least a portion of the first casted layer; depositing a second portion of the mold, on top of the first portion of the mold; pouring the liquid substance into the second portion of the mold to form a second casted layer, on top of at least a portion of the first casted layer; and solidifying at least a portion of the second casted layer. The method may further include joining the first and second casted layers prior to the pouring of a third casted layer.