Consumable Pattern Casting Mold Core Support
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Solution Overview
Problem
Consumable-pattern casting methods for cooling plates with serpentine-shaped tubular cores face challenges such as warping, porosity defects, and machining issues due to the lack of adequate support, leading to material waste and increased costs.
Innovation Solution
A method involving a mold core with support members, where the core is positioned within a negative mold, and support members are placed outside the consumable pattern to provide stability and rigidity during casting, allowing for unobstructed coolant flow and reduced porosity defects by maintaining the core's position and shape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If support bars are affixed directly to the serpentine tube to increase rigidity, then the mold core maintains its position and shape during casting, but the support bars obstruct the flow of molten aluminum and create porosity defects in the final casting
Solution Approach 1:
The support structure is divided into multiple discrete support bars positioned at specific intervals along the serpentine tube, rather than using continuous support. This segmentation allows the tube to maintain its shape while providing localized support that minimizes obstruction to molten aluminum flow.
Solution Approach 2:
Support bars are strategically positioned at specific locations along the serpentine tube where additional rigidity is most needed, rather than uniformly distributing support throughout. This local quality approach provides maximum stability where required while minimizing interference with the casting process elsewhere.
2Temperature
If the cooling plate is made thin to increase thermal contact with coolant, then thermal efficiency is improved, but the mold core becomes more susceptible to warping and deformation from molten aluminum heat
Solution Approach 1:
The serpentine tube is pre-formed with a rigid structure and positioned within the mold before casting. The mold itself provides preliminary support and constraint to prevent warping during the casting process, counteracting the thermal expansion and deformation forces that would otherwise occur.
Solution Approach 2:
The cooling plate geometry is pre-defined through the mold design, which incorporates the serpentine tube configuration. This preliminary action ensures that the tube maintains its intended shape and position throughout the casting process, preventing deformation before it can occur.
3Length of moving object
If the serpentine tube is made long to increase thermal contact length, then heat dissipation capability is improved, but the tube becomes more prone to warping and deforming from molten aluminum heat
Solution Approach 1:
The long serpentine tube is supported by multiple discrete support bars positioned at intervals along its length. This segmentation approach provides distributed support that prevents warping throughout the entire tube length while maintaining the tube's serpentine configuration for maximum thermal contact.
Solution Approach 2:
The support structure extends in multiple dimensions around the serpentine tube, providing three-dimensional support that constrains the tube against warping. This multi-dimensional support system maintains the tube's shape stability despite its extended length and curved configuration.
Data Source
AI summary
A method of making a casting is disclosed. At least one support member has at least one first portion and a plurality of second portions connected to a mold core. The mold core is positioned at least in part in a sealed interior volume of a negative mold. The first portion is positioned outside the interior volume. The second portions are positioned at least in part inside the interior volume. A consumable pattern material is introduced into the negative mold to create a consumable pattern. The support member is disposed at least in part outside the consumable pattern. The consumable pattern is removed from the negative mold. A shell is formed around the consumable pattern. A casting material is introduced into an interior of the shell to create a final casting. The support member is disposed at least in part outside the final casting. A mold core is also described.