Patent ID: 6050325
Filing Date: 2000-04-18
Classification: B22C

Abstract:
A method of casting an article having a thin wall portion with a thickness of 0.060 inches or less, a width of at least four inches, and a height of at least six inches, said method comprising the steps of providing an article pattern having at least a portion with a configuration corresponding to the configuration of the thin wall portion of the article, providing a reinforcing pattern which is spaced from the portion of the article pattern having a configuration corresponding to the thin wall portion of the article, covering both the article pattern and the reinforcing pattern with a coating of wet ceramic material which encloses the article pattern and the reinforcing pattern, said step of covering the article pattern and the reinforcing pattern with a coating of wet ceramic material includes filling space between the portion of the article pattern having a configuration corresponding to the configuration of the thin wall portion of the article and the reinforcing pattern with wet ceramic material, forming a mold structure and a reinforcing structure with a connecting body of ceramic material extending between the portion of the article pattern having a configuration corresponding to the thin wall portion of the article and the reinforcing pattern by drying the coating of wet ceramic material, removing the article pattern from the mold structure to leave a mold cavity having a configuration corresponding to the configuration of the article, conducting molten metal into the mold cavity, and transmitting force from a portion of the mold structure having a configuration corresponding to the configuration of the thin wall portion of the article to the reinforcing structure through the connecting body of ceramic material to support the portion of the mold structure having a configuration corresponding to the configuration of the thin wall portion of the article with the reinforcing structure.