公开(公告)号：US5927379A

公开(公告)日：1999-07-27

申请号：US719690

申请日：1996-09-26

申请人： Mehrdad Yasrebi ,  David Howard Sturgis ,  William Warren Kemp ,  Mark Edwin Springgate ,  Douglas Gene Nikolas

发明人： Mehrdad Yasrebi ,  David Howard Sturgis ,  William Warren Kemp ,  Mark Edwin Springgate ,  Douglas Gene Nikolas

IPC分类号： B22C1/16 ,  B22C9/02 ,  B22C9/04

CPC分类号： C04B35/505 ,  B22C1/165 ,  B22C1/167 ,  B22C9/02 ,  B22C9/04 ,  C04B35/481 ,  C04B35/4885 ,  C04B35/6316 ,  C04B2235/3225 ,  C04B2235/3244 ,  C04B2235/3418 ,  C04B2235/3427 ,  C04B2235/5436 ,  C04B2235/606 ,  C04B2235/61 ,  C04B2235/616 ,  Y10S977/811

摘要： Methods and compositions for forming shells for investment casting and methods for casting metal articles using the shells are described. One embodiment of the method comprises serially immersing a pattern in at least one, and perhaps several different slurries, each of which slurries comprises refractory material and from about 0 to about 30 volume percent inorganic binder. This forms a facecoat and plural refractory backup layers about the pattern, the facecoat and at least one backup layer defining a shell. The facecoat and/or the shell is then infiltrated with a binder. Infiltrating the shell with a binder is a key feature of the present invention. Infiltration refers to any process whereby a binder can be introduced into the facecoat and/or the subsequent layers built up about the shell. One method of infiltrating the facecoat and/or layers with binder comprises immersing the pattern having refractory material into a slurry comprising a binder, including inorganic binders, organic binders, and mixtures thereof. The pattern then is separated from the shell, forming a shell having an internal void in the shape of an article to be cast. Molten metal is then introduced into the void and allowed to solidify.

摘要翻译： 描述了用于熔模铸造的壳体的方法和组合物以及使用壳体铸造金属制品的方法。 该方法的一个实施方案包括将图案串联浸渍在至少一种，也可以是几种不同的浆料中，每种浆料中的每一种浆料包含耐火材料和约0至约30体积％的无机粘合剂。 这形成围绕图案的面漆和多个耐火后备层，面涂层和限定壳的至少一个支撑层。 然后用粘合剂渗透面漆和/或壳。 用粘合剂渗透壳体是本发明的关键特征。 渗透是指粘合剂可以被引入面罩中和/或围绕壳体建成的后续层的任何方法。 用粘合剂渗透面涂层和/或层的一种方法包括将具有耐火材料的图案浸入包括粘合剂的浆料中，所述粘合剂包括无机粘合剂，有机粘合剂及其混合物。 然后将图案与壳分离，形成具有待铸造制品形状的内部空隙的壳体。 然后将熔融金属引入空隙中并使其固化。该方法允许形成不含无机粘合剂的熔模铸造浆料，或允许形成仅具有少量无机粘合剂的浆料。 没有粘合剂或粘合剂浓度大的粘合剂的成型熔模浆料基本上延长了这种浆料的使用寿命。 此外，该方法提供具有良好的生坯强度，相对易于壳脱壳和可接受的蠕变的壳。

公开(公告)号：US5643844A

公开(公告)日：1997-07-01

申请号：US312694

申请日：1994-09-27

申请人： Mehrdad Yasrebi ,  Mark Edwin Springgate ,  Douglas Gene Nikolas ,  William Warren Kemp ,  David Howard Sturgis ,  Renee Van Ginhoven

发明人： Mehrdad Yasrebi ,  Mark Edwin Springgate ,  Douglas Gene Nikolas ,  William Warren Kemp ,  David Howard Sturgis ,  Renee Van Ginhoven

IPC分类号： C04B35/505 ,  C04B35/626

CPC分类号： C04B35/626 ,  C04B35/505

摘要： Time-stable yttria slurries, and a method for forming such yttria slurries and articles therefrom are described. The method involves forming an intimate mixture comprising yttria and at least about 0.1 weight percent of a dopant material. An aqueous slurry is then formed comprising from about 1 weight percent to about 95 weight percent of the intimate mixture. The intimate mixture may be formed by heating the mixture to a temperature sufficient to calcine the mixture. Alternatively, the intimate mixture may be formed by heating the mixture to a temperature sufficient to fuse the mixture. The dopant also may be provided as a surface coating on the yttria particles. The dopant material comprises an oxide or hydroxide, or combinations thereof, or compounds that form such oxides or hydroxides upon further processing, wherein the metal oxides or hydroxides are of metals selected from the group consisting of aluminum, titanium, niobium, tantalum, silicon, hafnium, tin, gallium, indium, beryllium, thorium, boron, scandium, vanadium, chromium, ruthenium, rhodium, iridium, palladium, platinum, copper, germanium, bismuth, tellurium, erbium, thulium, ytterbium, lutetium, neptunium, plutonium, and combinations thereof. The aqueous suspension may further comprise other materials, such as other ceramic or metallic particles, co-solvents, dispersing agents, surfactants, inorganic binders, or organic binders.

摘要翻译： 描述了时间稳定的氧化钇浆料，以及用于形成这种氧化钇浆料和制品的方法。 该方法包括形成包含氧化钇和至少约0.1重量％掺杂剂材料的紧密混合物。 然后形成包含约1重量％至约95重量％的紧密混合物的含水浆料。 可以通过将混合物加热到足以煅烧混合物的温度来形成紧密混合物。 或者，可以通过将混合物加热到足以熔化混合物的温度来形成紧密混合物。 掺杂剂也可以作为氧化钇颗粒上的表面涂层提供。 掺杂剂材料包括氧化物或氢氧化物或其组合，或在进一步加工时形成这种氧化物或氢氧化物的化合物，其中金属氧化物或氢氧化物是选自铝，钛，铌，钽，硅， 铪，锡，镓，铟，铍，钍，硼，钪，钒，铬，钌，铑，铱，钯，铂，铜，锗，铋，碲，铒，ium，镱，镥，ium，钚， 及其组合。 水性悬浮液还可包含其它材料，例如其它陶瓷或金属颗粒，共溶剂，分散剂，表面活性剂，无机粘合剂或有机粘合剂。

公开(公告)号：US06920913B2

公开(公告)日：2005-07-26

申请号：US10431881

申请日：2003-05-07

申请人： Mehrdad Yasrebi ,  Karl Milton Taft, III ,  David Howard Sturgis ,  Michael Gerald Sorbel ,  Mark E. Springgate ,  Douglas Gene Nikolas

发明人： Mehrdad Yasrebi ,  Karl Milton Taft, III ,  David Howard Sturgis ,  Michael Gerald Sorbel ,  Mark E. Springgate ,  Douglas Gene Nikolas

IPC分类号： B22C20060101 ,  B22C1/02 ,  B22C1/22 ,  B22C9/00 ,  B22C9/04 ,  B22C11/00 ,  B28B7/34 ,  B28B7/36

CPC分类号： C04B35/111 ,  C04B35/505 ,  C04B35/624 ,  C04B35/6264 ,  C04B35/62645 ,  C04B35/62655 ,  C04B35/6303 ,  C04B35/6316 ,  C04B2235/3225 ,  C04B2235/6027

摘要： Embodiments of a method for increasing the lifetime of a casting slurry are described. One feature of the disclosed embodiments comprises processing refractory materials that are used to form casting slurries to provide a substantial increase in slurry lifetime for slurries made using such processed materials compared to slurries made using materials not processed as described herein. One embodiment of the method comprises heat processing at least one refractory powder. Without limiting the invention to a theory of operation, processing is continued for a period of time sufficient to reduce the amount of hydration from a first hydration level to a second hydration level. A slurry is formed using the refractory powder at a hydration level which provides an increased slurry lifetime relative to the same material without processing according to the disclosed embodiments.

摘要翻译： 描述了用于提高铸造浆料的寿命的方法的实施例。 所公开的实施方案的一个特征包括加工用于形成浇注浆料的耐火材料，以提供使用这种加工材料制备的浆料的浆料寿命的显着增加，与使用如本文所述未加工的材料制成的浆料相比。 该方法的一个实施方案包括热处理至少一种耐火粉末。 在不将本发明限于操作理论的情况下，继续处理足以将水合量从第一水合水平降低到第二水化水平的时间。 使用难熔粉末以水合水平形成浆料，其相对于相同的材料提供了增加的浆料寿命，而根据所公开的实施方案不进行处理。

公开(公告)号：US06390179B1

公开(公告)日：2002-05-21

申请号：US09710545

申请日：2000-11-08

申请人： Mehrdad Yasrebi ,  Karl Milton Taft, III ,  David Howard Sturgis ,  Michael Gerald Sorbel ,  Mark E. Springgate ,  Douglas Gene Nikolas

发明人： Mehrdad Yasrebi ,  Karl Milton Taft, III ,  David Howard Sturgis ,  Michael Gerald Sorbel ,  Mark E. Springgate ,  Douglas Gene Nikolas

IPC分类号： B22C900

CPC分类号： C04B35/111 ,  C04B35/505 ,  C04B35/624 ,  C04B35/6264 ,  C04B35/62645 ,  C04B35/62655 ,  C04B35/6303 ,  C04B35/6316 ,  C04B2235/3225 ,  C04B2235/6027

摘要： Methods for increasing the lifetime of a casting slurry are described. One feature of the invention is processing refractory powders at a first hydration level to produce powders having a second, lower hydration level before the processed materials are used to form casting slurries. Processing according to the disclosed methods results in a substantial increase in the lifetime of a slurry made using such processed materials compared to slurries made using materials not processed as described herein. One embodiment of the method comprises heat processing at least one refractory powder, typically refractory powders which have undergone hydration subsequent to commercial production, for a period of time sufficient to reduce the amount of hydration from a first hydration level to a second hydration level. A slurry is formed using the refractory powder at an hydration level which provides an increased slurry lifetime relative to the same material without processing according to the method of the present invention. Slurry formation can be accomplished substantially immediately after processing, or up to about one week after processing, typically less than 24 hours after processing, and even more typically within 2 hours to about 8 hours after processing.

摘要翻译： 描述了提高铸造浆料寿命的方法。 本发明的一个特征是在第一水合水平下加工难熔粉末，以在加工的材料用于形成浇注浆料之前产生具有第二较低水化水平的粉末。 根据所公开的方法的加工，与使用如本文所述未加工的材料制成的浆料相比，导致使用这种加工材料制成的浆料的使用寿命显着增加。 该方法的一个实施方案包括热处理至少一种耐火粉末，通常在商业生产后经历水合的耐火粉末足以将水合量从第一水合水平降低至第二水化水平。 使用难熔粉末以水合水平形成浆料，其相对于相同的材料提供了增加的浆料寿命，而不是根据本发明的方法进行处理。 浆料形成可以在加工之后基本上立即完成，或者在加工之后至多约一周，通常在加工后通常小于24小时，甚至更通常在加工后2小时至约8小时内完成。

公开(公告)号：US06619368B1

公开(公告)日：2003-09-16

申请号：US09602671

申请日：2000-06-26

申请人： Mark E. Springgate ,  James R. Barrett ,  David Howard Sturgis ,  Douglas G. Nikolas ,  Mehrdad Yasrebi

发明人： Mark E. Springgate ,  James R. Barrett ,  David Howard Sturgis ,  Douglas G. Nikolas ,  Mehrdad Yasrebi

IPC分类号： B22D102

CPC分类号： B22C9/04 ,  B22D46/00 ,  B82Y30/00 ,  C04B35/50 ,  C04B35/505 ,  C04B35/6316 ,  C04B2235/3224 ,  C04B2235/3225 ,  C04B2235/3232 ,  C04B2235/3418 ,  C04B2235/5454

摘要： A method for imaging inclusions in metal or metal alloy castings is described. One embodiment of the present method first involves casting a metal or metal alloy article using an investment casting mold where the mold facecoat, and perhaps one or more of the mold backup layers, comprises an imaging agent distributed substantially uniformly throughout in amounts sufficient for imaging inclusions. The facecoat preferably comprises an intimate mixture of a refractory material and the imaging agent. Intimate mixtures can be produced in a number of ways, but a currently preferred method is to cocalcine the refractory material, such as yttria, with the imaging agent, such as gadolinia. The facecoat also can comprise plural mold-forming materials and/or plural imaging agents. The difference between the linear attenuation coefficient of the article and the linear attenuation coefficient of the imaging agent should be sufficient to allow imaging of the inclusion throughout the article. The metal or metal alloy article is then analyzed for inclusions by N-ray analysis. The method also can include the step of analyzing the metal or metal alloy by X-ray analysis. The imaging agent, typically a metal oxide or salt, comprises a material selected from the group consisting of boron, neodymium, samarium, europium, gadolinium, dysprosium, holmium, erbium, ytterbium, lutetium, iridium, physical mixtures thereof and chemical mixtures thereof.

公开(公告)号：US6102099A

公开(公告)日：2000-08-15

申请号：US212116

申请日：1998-12-15

申请人： David Howard Sturgis ,  James R. Barrett ,  Mark E. Springgate ,  Mehrdad Yasrebi ,  Douglas G. Nikolas

发明人： David Howard Sturgis ,  James R. Barrett ,  Mark E. Springgate ,  Mehrdad Yasrebi ,  Douglas G. Nikolas

IPC分类号： B22C1/02 ,  B22C3/00 ,  B22C9/04 ,  B22C9/06

CPC分类号： B22C1/02

摘要： A metal or metal alloy article is cast using an investment casting mold where the mold facecoat, and perhaps one or more of the mold backup layers, comprises an imaging agent distributed substantially uniformly throughout in amounts sufficient for imaging inclusions. The facecoat preferably comprises an intimate mixture of a refractory material and the imaging agent. Intimate mixtures can be produced in a number of ways, but a currently preferred method is to cocalcine the refractory material, such as yttria, with the imaging agent, such as gadolinia. The facecoat also can comprise plural mold-forming materials and/or plural imaging agents. The difference between the linear attenuation coefficient of the article and the linear attenuation coefficient of the imaging agent should be sufficient to allow imaging of the inclusion throughout the article. The metal or metal alloy article is then analyzed for inclusions by N-ray analysis. The method also can include the step of analyzing the metal or metal alloy by X-ray analysis. The imaging agent, typically a metal oxide or salt, comprises a material selected from the group consisting of boron, neodymium, samarium, europium, gadolinium, dysprosium, holmium, erbium, ytterbium, lutetium, iridium, physical mixtures thereof and chemical mixtures thereof.

摘要翻译： 使用熔模铸造模具铸造金属或金属合金制品，其中模具面漆以及可能的一个或多个模具支撑层包括基本上均匀分布的成像剂，其量足以成像夹杂物。 面漆优选包含耐火材料和成像剂的紧密混合物。 密实混合物可以以多种方式生产，但目前优选的方法是与诸如氧化钆之类的成像剂共存耐火材料，例如氧化钇。 面罩还可以包括多个成型材料和/或多个成像剂。 制品的线性衰减系数与成像剂的线性衰减系数之间的差异应足以允许整个制品中包含的成像。 然后通过N线分析分析金属或金属合金制品的夹杂物。 该方法还可以包括通过X射线分析分析金属或金属合金的步骤。 成像剂（通常为金属氧化物或盐）包括选自硼，钕，钐，铕，钆，镝，钬，铒，镱，镥，铱，其物理混合物及其化学混合物的材料。

公开(公告)号：US06326429B1

公开(公告)日：2001-12-04

申请号：US09366804

申请日：1999-08-04

申请人： David Howard Sturgis ,  Mehrdad Yasrebi ,  Karl Milton Taft, III ,  Michael Gerald Sorbel

发明人： David Howard Sturgis ,  Mehrdad Yasrebi ,  Karl Milton Taft, III ,  Michael Gerald Sorbel

IPC分类号： C08K501

CPC分类号： C08K5/01 ,  B22C7/02 ,  C08L69/00

摘要： Wax compositions that are useful, amongst other things, for forming investment casting patterns are described. One embodiment of the wax composition comprises: (a) pattern wax; and (b) from about 1% to about 85% by weight of a polymeric organic carbonate filler material. Examples of particular polymeric organic carbonate filler materials include, without limitation, polyethylene carbonate, polypropylene carbonate, poly(cyclohexane carbonate), poly(cyclohexane propylene carbonate), and mixtures thereof. Crosslinking the organic portion of the polymeric organic carbonate filler material can substantially reduce its thermal expansion. The wax compositions generally include other materials commonly used to form wax compositions. Such materials include waxes and resinous materials, conventional fillers, ultra-violet curable monomers, plasticizers, lubricants, and mixtures thereof. Conventional fillers, including urea, can be copolymerized with the polymeric organic carbonate filler material to reduce the dissolution and/or agglomeration of the filler. Wax patterns useful for forming investment casting molds are then made from such compositions using conventional techniques, such as injection molding. The patterns are serially immersed in slurries comprising refractory materials to form casting molds. Metal and metal alloy articles are then cast using such molds.

摘要翻译： 描述了用于形成熔模铸造图案的蜡组合物。 蜡组合物的一个实施方案包括：（a）图案蜡; 和（b）约1％至约85％重量的聚合有机碳酸酯填料。 特定的聚合有机碳酸酯填料材料的实例包括但不限于聚碳酸亚乙酯，聚碳酸亚丙酯，聚（环己烷碳酸酯），聚（环己烷碳酸亚丙酯）及其混合物。 交联聚合有机碳酸酯填料的有机部分可以显着降低其热膨胀。 蜡组合物通常包括通常用于形成蜡组合物的其它材料。 这些材料包括蜡和树脂材料，常规填料，紫外线固化性单体，增塑剂，润滑剂及其混合物。 常规的填料，包括尿素，可与聚合有机碳酸酯填料共聚，以减少填料的溶解和/或附聚。 然后使用常规技术（例如注塑）从这样的组合物制备用于形成熔模铸造模具的蜡图案。 将图案串联浸入包含耐火材料的浆料中以形成铸模。 然后使用这种模具铸造金属和金属合金制品。