Abstract:
Procédé de fabrication d'un modèle pour fonderie à modèle perdu dans lequel on fournit au moins un insert (10); on fournit au moins deux portions (12,14) du modèle, lesdites au moins deux portions étant réalisées dans un matériau éliminable; et on assemble de manière étanche lesdites au moins deux portions de modèle autour d'au moins une partie dudit au moins un insert de manière à réaliser ledit modèle (16).
Abstract:
A method of casting a component (42) having convoluted interior passageways (44). A desired three dimensional structure corresponding to a later-formed metal alloy component is formed by stacking a plurality of sheets (18, 20) of a fugitive material. The sheets contain void areas (22) corresponding to a desired interior passageway in the metal alloy component. A ceramic slurry material is cast into the three dimensional structure to form either a ceramic core (34) or a complete ceramic casting vessel (38). If just a ceramic core is formed, a wax pattern is formed around the ceramic core and an exterior ceramic shell (38) is formed around the wax pattern by a dipping process prior to the removal of the fugitive material and wax. An alloy component having the desired interior passageway is cast into the casting vessel after the fugitive material is removed
Abstract:
A multi-wall ceramic core assembly and method of making same wherein a plurality of individual thin wall, arcuate (e.g. airfoil shaped) core elements (C1, C2, C3) are formed in respective master dies to have integral interlocking locating features (10a, 10b), the individual core elements are prefired in respective ceramic setter supports to have integral locating features, the prefired core elements are assembled together using the locator features of adjacent core elements, and the assembled core elements are adhered together using ceramic adhesive introduced at internal joints defined between mating interlocked locating features. The multi-wall ceramic core assembly so produced comprises the plurality of spaced apart thin wall, arcuate core elements and joined together by at the internal joints defined between the adhered interlocked locating features.
Abstract:
A bearing housing, or integrated turbocharger housing, with the oil, and optionally air and water galleries, included as as-cast features, thereby avoiding the problems, design limitations and expense associated with conventional post-casting machining. The method of casting preferably uses lost foam casting, or a technique similar to lost foam casting but in which a ceramic shell is formed on the foam form prior to metal casting, but can use any of a variety of casting techniques or a combination of two or more techniques.
Abstract:
Die Erfindung betrifft ein Verfahren zur Herstellung einer elektrischen Maschine (1), bestehend aus einem Gehäuse (2), einem in dem Gehäuse (2) aufgenommen Stator (3), der zumindest aus einem Statorkörper (19) und Statorwicklungen (20) gebildet wird, einem Rotor (4), der in dem Gehäuse (2) drehbar um eine Rotorachse (5) gelagert wird und einem an dem Gehäuse (2) befestigten Lagerschild (11), wobei das Gehäuse (2) hergestellt wird, indem ein Gehäuseschäumteils (22) aus zumindest drei Einzelschäumteilen (23, 24, 25) hergestellt wird und ein Gehäusegussrohling (122) mittels des Gehäuseschäumteils (22) nach einem Lost-Foam-Gussverfahren hergestellt wird. Dabei werden die Einzelschäumteile (23, 24, 25) aus einer Mittelscheibe (24), die eine im Wesentlichen hohlzylindrische Bauform aufweist und ein Zwischenstück des Gehäuseschäumteils (22) bildet, einer Ringscheibe (25), die eine im Wesentlichen hohlzylindrische Bauform aufweist und ein weiteres Zwischenstück des Gehäuseschäumteils (22) bildet und einer Lagerschildscheibe (23), die eine im wesentlichen topfförmige Bauform aufweist und ein Ende des Gehäuseschäumteils (22) bildet, gebildet. Das erfindungsgemäße Verfahren ermöglicht eine flexible Gestaltung des Gehäuses (2) der elektrischen Maschine (1) bei möglichst wenigen Werkzeugen zur Herstellung des Gehäuseschäumteils (22).
Abstract:
Method for making a multi-wall ceramic core for use in casting airfoils, such as turbine blades and vans, wherein a fugitive pattern (20) having multiple thin wall pattern elements (P1), (P2), (P3) corresponding to internal wall-forming spaces of a final core is formed, the pattern is placed in a core molding die cavity (30) having a desired core configuration, a fluid ceramic material is introduced into the die cavity about the pattern and between the pattern elements to form a ceramic core (10), and the core is removed from the die cavity. The fugitive pattern is selectively removed from the core to provide a multi-wall green core. The green core then is fired to develop core strength for casting and used to form an investment mold (M) for casting an airfoil.
Abstract:
Investment casting pattern fasteners are described. One embodiment comprises a first fastener portion that defines a receiving end, and a second fastener portion that defines an insert portion for insertion into the first fastener portion. At least one of the first and second fastener portions, and perhaps, both, typically has a reverse draft structure to help secure such fastener portion in the pattern material. The first fastener portion and/or the second fastener portion may have substantially smooth surfaces, or may be textured or ribbed. The fasteners also may include a wax- or polymeric-receiving portion, such as a wax-receiving indentation in an exterior surface thereof and/or a wax receiving orifice. Other structural features also can be used to help secure the fasteners in the pattern material, such as an anchoring spine, or spines, that projects outwardly from an external surface of the first or second fastener portion. Working embodiments of four-piece and five-piece fasteners have been made. An investment casting pattern also is described. The pattern comprises plural pattern components, and at least one fastener as described above used to couple components of the pattern together. The present invention also provides a method for forming an investment casting pattern. The method comprises first providing plural pattern components having a pattern component fastener, such as those described above, positioned therein. The plural wax pattern components are joined together using such fasteners. The present invention addresses the problems associated with wax welding techniques. The fasteners of the present invention and method for using such fasteners to couple pattern components together have been found to reduce pattern assembly time by as much as 30 %.