Investment Casting Pattern Fastener Alignment
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Solution Overview
Problem
Misalignment of body portions in investment casting patterns can lead to unwanted surface and structural defects in components, reducing efficiency and potentially requiring scrapping, due to the lack of a reliable alignment method independent of operator skill.
Innovation Solution
A multi-part investment casting pattern with a fastener made of a different material than the body portions, which provides a positive location feature for aligning and joining the parts, formed using additive layer manufacturing and capable of being removed during the casting process, thereby reducing manual assembly steps and ensuring consistent alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual assembly methods are used to join pattern parts, then flexibility in assembly is maintained, but alignment precision deteriorates due to operator skill variability
Solution Approach 1:
The fastener acts as an intermediary component between the first and second body portions, providing a standardized interface that ensures precise alignment. The fastener includes locating features such as pins or protrusions that fit into corresponding recesses, creating a repeatable geometric relationship between parts regardless of operator skill level.
Solution Approach 2:
The invention changes the material parameter of the fastener to have a higher melting point than the body portions. This allows the fastener to remain intact during the investment casting process while the wax body portions are removed, providing both alignment during assembly and automatic separation during casting.
2Manufacturing precision
If multiple manual steps are used to assemble and align pattern parts, then alignment precision can be improved, but manufacturing time increases
Solution Approach 1:
The fastener combines multiple functions into a single component: it provides mechanical joining of the body portions, precise alignment through locating features, and controlled removal during casting. This integration eliminates the need for separate alignment tools, adhesives, and removal processes, streamlining the entire workflow.
Solution Approach 2:
The fastener is designed to be self-locating and self-aligning through its geometric features. The locating pins or protrusions automatically guide the body portions into correct alignment when the fastener is inserted, eliminating the need for manual measurement and adjustment steps.
3Stability of the object's composition
If the fastener is made of the same material as the body portions, then material consistency is maintained, but removal during casting becomes problematic
Solution Approach 1:
The fastener has different material properties than the body portions specifically at the location where removal is needed. The higher melting point of the fastener material allows it to remain stable during the casting process while the lower melting point body portions are removed, creating the desired void.
Solution Approach 2:
The pattern is constructed as a composite structure with two different materials: the body portions made of low-melting-point wax and the fastener made of high-melting-point material. This composite approach allows each material to serve its specific function - the wax provides the pattern shape that is easily removed, while the fastener provides structural integrity during assembly and controlled removal timing.
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
The use of a fastener with a higher melting point than the body portions ensures accurate alignment and joining, reducing defects and improving manufacturing efficiency by simplifying the assembly process and ensuring consistent alignment, independent of operator skill.
Implementation Method 1
The first body portion and the second body portion may be formed of a first material having a first melting temperature. The fastener may be formed of a second material, having a second melting temperature greater than or approximately equal to the first melting temperature.
Implementation Method 2
The pattern is then removed from the mould, by melting or chemical leaching (dissolving) to leave a void in the mould
Data Source
AI summary
An investment casting pattern including: a consumable body formed of: a first body portion; and a second body portion; and a fastener arranged to form an interface between the first body portion and the second body portion, and to locate the first body portion relative to the second body portion, wherein the fastener is formed of a different material than the first body portion and the second body portion.