An investment casting process for producing castings

Abstract: An investment casting process is carried out by the formation of a lost pattern in a lost mold and its ceramic coating once formed. The process comprises the following steps: 1) Manufacturing a positive pattern (i.e., with the same shape as the casting to be made) either with hard or elastic material, depending on the cases. 2) Manufacturing a temporary mold by pouring a liquid over the positive pattern and cooling it up to its solidification. 3) Extracting the positive pattern. 4) Forming a temporary pattern by pouring a second liquid into the cavity of the temporary mold and cooling it up to its solidification. 5) Melting or solving the temporary mold. 6) Coating the temporary pattern with ceramics, forming a solid ceramic shell around the temporary pattern. 7) Melting or solving out the temporary pattern and evacuating the resulting liquid from the ceramic shell. 8) Filling the shell cavity with molten metal which is allowed to solidify to form the final cast piece. The process allows the production of all types of top quality cast parts as it makes possible -irrespective of their complexity- forming a lost pattern in a lost mold, thus avoiding the risk of breakage of lost patterns as well as the need of using cores (with high deformation risks). In addition recyclable materials are used in the production of the lost patterns and molds.

Description: The present invention relates to an investment casting process used to produce casting pieces by means of the achievement of a ceramic coated lost pattern and said pattern being made through a lost pattern BACKGROUND OF THE INVENTION The present invention offers substantial improvements in the investment casting process, those being: "Lost Wax" and "Temporary Pattern by freezing a liquid in an elastic mold". Both processes allow for the manufacture of high quality castings. However, each process presents a number of drawbacks. a) PROCESS "LOST WAX" The main disadvantages of this process originate in the transformation and handling of the used wax for the manufacturing pattern. 1) The high cost of the necessary tooling for the injection of the wax, which makes this process profitable only for pieces to be manufactured on a large scale. 2) The complexity of the handling of the wax patterns, resulting in a high cost of manpower in the preparation of clusters or multiple patterns. 3) Difficulty and decline in quality of the waxes when recycled. b) PROCESS "FORMING A TEMPORARY PATTERN BY FREEZING A LIQUID IN AN ELASTIC MOLD" Due to the fact that the casting process by means of ceramic coating is directed to the production of precise parts with thin wall thickness and intricate shapes, the main drawbacks of this process are: 1) The enormous difficulty in the extraction of the temporary pattern from the elastic mold without causing any cracks in the pattern when thin walls must be obtained. 2) The difficulty of manufacturing pieces that require complex cores, which lead to the imperative use of ceramic cores hence incurring an increase in the price of the product. 3) Difficulty in the extraction of complete clusters from the elastic mold without causing any cracks. German Patent DE-1 034 844 is known, through which destructible molds are used for the production of moulding bodies of melting elastomers such as the polyurethane. These mols are destroyed by dissolution, bearing in mind that these dissolvents do not have to attack the moulding bodies. Magazine TOOLING AND PRODUCTION, vol. 44, no. 11 (1979.02) shows the manufacture of complex patterns made by means of different parts sticking which will form the final pattern. Finally, Patent US-2 480 048 is also known, which relates to a casting process which uses a low fusing mold which may readily be removed from the article cast. This mold if formed by a melting metal at a temperature which does not cause any damage to the casting metal. SUMMARY OF THE INVENTION With this invention the said drawbacks of the current investment casting processes are overcome and remedied by providing a precise and improved casting process of higher rapidity of performance and better finished pieces by means of a ceramic coating of a lost pattern, in which, and as distinguished advantage the lost pattern is formed in a lost mold, which produces the following advantageous effects: A) The manufacture of all types of pieces - including those which are extremely thin or that require complex cores - avoiding both the risk of cracking and the use of cores. B) The manufacture of all types of high quality pieces irrespective of their complexity, and for large, medium and short series with a minimum investment in tooling which makes for a profitable manufacture of such complex pieces for large, medium and short series. C) The manufacture of all types of high quality pieces using recyclable materials in the manufacturing of lost patterns and molds which entails low preparation costs of lost patterns and molds. D) The manufacture of all types of high quality pieces even when it is necessary to prepare complete clusters (multiple patterns) with no risks of cracks, which entails low handling costs of the lost patterns. The casting process, carried out as specified below, for producing castings by means of ceramic coating of a lost pattern formed in a lost mold. Taking a positive mould, a temporary mould is formed by pouring a liquid over the mould and cooling it below its melting point to a sold state this temporary mould may be formed by manifold pieces which join between each other when the piece shape is complex. The pattern is extracted from the temporary mold and a temporary pattern is formed by pouring a second liquid, allowing this to cool until it reaches a solid state. The temporary mold is eliminated by melting the same through the adequate control of the temperature (or by solving the temporary mold in an adequate solvent) obtaining the temporary pattern. The ceramic coating is made around the temporary pattern. The temperature is raised above the melting temperature of the second liquid in order to cause the melting and evacuation of the temporary pattern, obtaining a ceramic shell whose cavity has the same shape as the piece to be cast. The cavity of the ceramic shell is filled with molten metal, which is allowed to solidify to form the final piece. BRIEF DESCRIPTION OF THE DRAWINGS The character of this invention may be best understood by reference to the attached drawings which describe one way of carrying out the invention, in particular the method which entails the elimination of the temporary mold by melting of the same. Fig. 1 - Description of the necessary tooling equipment to begin the manufacturing process (positive mould of elastic material). Fig. 2 - Description of the parts of the temporary mold formed upon extracting the elastic pattern from the solidified material within the same. Fig. 3 - Description of the temporary mold formed by the assembly of its different parts. Fig. 4 - Description of the ensemble formed after pouring a liquid into temporary mold. Fig. 5 - Description of temporary pattern formed upon melting temporary mould. Fig 6 - Description of the ensemble formed by the ceramic coating of the temporary pattern. Fig. 7 - Description of the cavity formed upon melting pattern and its evacuation from the ceramic shell. Fig. 8 - Description of the ensemble formed by pouring and solidification of the molten metal inside the ceramic shell. Fig. 9 - Description of the cast piece obtained upon eliminating the shell and all left over material. DETAILED DESCRIPTION OF THE INVENTION The process starts with the manufacture of a positive mould, generally formed by a layer of elastic material (1) which sits on a rigid support piece (2). This mould may reproduce one or various pieces, depending on the size and shape of the same. Liquid (3) is poured in the interior of the different parts of the positive mould, and te ensemble is cooled to a temperature T(1), lower than the melting point of liquid (3) resulting in the solidification of the same. The cooled liquid (3) is then extracted, obtaining the different parts of the temporary mold (4,5) (see Fig.2). A temporary mold is formed by assembling the corresponding parts (6) (see Fig.3) Keeping the temperature at T(1), liquid (7) is poured in the interior of the temporary mold (4,5). The relation between the melting temperature of (3) and (7) must be the following: T(3) < T(7) T(3) and T(7) being the melting temperatures of materials (3) and (7) respectively. The temperature of liquid (7), at the time in which it is poured into the temporary mold, must be close to its solidifying temperature. Given that the temporary mold is at a temperature T(1) lower than the melting point of (3) T(3), and, therefore, sensibly lower than the solidification temperature of the liquid (7), the solidification of same will be obtained. Now, the temperature of the unit "temporary mold-temporary pattern" is brought to a temperature T(2) between the melting points of (7) and (3). T(3) < T(2) < T(7) At this temperature T(2), the melting of the temporary mold (4,5) is produced, hence the temporary pattern (7) is the only one that remains in a solid state (see Fig.5) Maintaining the pattern (7) at temperature T(2), the coating of same is formed by dipping it into a ceramic slurry whose solidification temperature should be lower than T(2); thus, the coating process is carried out by conventional means (see Fig.6) Next, the temperature of the unit is raised above T(7) (melting point of (7)), so that the temporary pattern (7) is melted and evacuated from the interior of the ceramic shell by inverting the position of the shell (see Fig.7). The next steps such as: drying of the ceramic shell, filling the same with molten metal, allowing the metal to solidify, eliminating the shell which is stuck to the cast piece and eliminating any left over material (feeding system of the pieces) are all carried out by conventional procedures (see Figs. 8 and 9).

Claims: An investment casting process for producing castings which starts from the formation of a positive mould which consists of one or several parts, depending upon the casting to be reproduced, such positive mould being made of two sections, a first section or rigid support (2) and a second section or cover comprising an elastic material (1), a liquid (3) is poured over the mould or moulds thus formed which is then cooled until it hardens, whereupon it is removed and assembled with other sections if the mould is made of several parts to form a temporary mould (4,5), a second liquid (7) having a melting point greater than that of the former liquid (3) being poured into the mould formed, this second liquid being thereupon hardened within the temporary mould (4,5), the temporary mould (4,5) being then melted by submitting it to a temperature above the melting point of the liquid from which the mould shall have been drawn, albeit less than the melting point of the inner liquid poured into the temporary mould (4,5), the result being the inner hardened part or pattern (7) which is coated with ceramics, forming a solid ceramic shell around the temporary pattern, melting or solving out the temporary pattern and evacuating the resulting liquid from the ceramic shell and filling the ceramic shell cavity with molten metal which is allowed to solidify to form the final cast piece. An investment casting process for producing castings as in claim 1, characterised in that the hardening temperature of the liquid forming the temporary mould (4,5) or sections of the mould is less than the hardening temperature of the second liquid to be poured into the same and which shall constitute the pattern (7) in the casting process.

Inventors: DE ANTONIO GONALONS JUAN, INSAUSTI MARTINEZ DE LAHIDALGA, DE ANTONIO GONALONS, JUAN, INSAUSTI MARTINEZ DE LAHIDALGA, RICARDO
Applicants: ANTONIO GONALONS JUAN DE, INSAUSTI MARTINEZ DE LAHIDALGA, DE ANTONIO GONALONS, JUAN, INSAUSTI MARTINEZ DE LAHIDALGA, RICARDO
Application year: 1993
Main classification: B22C7
IPC codes: B22C9, B22C7, B22D25