Casting process and cast product

Abstract

A process for forming a cast product or component, including one or more parts having a passage or cavity on at least one side such as a stator or rotor from aluminium or magnesium alloy, comprises supporting one or more preformed insert or inserts for example stainless steel in association with a mould part or parts which define(s) the passage or cavities during the casting process, surrounding the mould part(s) with one or more other mould parts which define the balance of the product or component shape, filling the mould with molten material, and allowing the product to cool and removing the mould parts to leave the cast product with the preformed inserts cast in situ as an integral part or parts of the cast product or component. Typically the process is a sand casting process. Typically the preformed insert(s) are formed of a stronger or more wear-resistant material than the material from which the balance of the product is cast, such as stainless steel.

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       14 . A process for forming a cast stator or rotor component, which includes a number of radially extending vanes or blades, comprising supporting preformed inserts, each of which in the cast stator or rotor component will form a leading portion of a vane or blade of the rotor or stator component, in association with a mould part or parts which define(s) passages between the vanes or blades during the casting process, surrounding the mould part(s) with one or more other mould parts which define the balance of the stator or rotor component shape, filling the mould with molten material, and allowing the molten material to cool and removing the mould parts to leave the cast stator or rotor component with each preformed insert cast in situ as an integral leading portion of a vane or blade with a trailing portion of the vane or blade being formed of the material from which the balance of the stator or rotor component is cast, said preformed inserts being formed of a stronger or more wear-resistant material than the material from which the balance of the product is cast.  
   
   
       15 . A process according to  claim 14  wherein at least some of said mould parts are formed of sand by sand casting.  
   
   
       16 . A process according to  claim 15  wherein the preformed inserts are formed from stainless steel.  
   
   
       17 . A process according to  claim 16  wherein the balance of the stator or rotor is cast from a metal selected from the group consisting of aluminum, an aluminum alloy, magnesium, and a magnesium alloy.  
   
   
       18 . A process according to  claim 14  wherein the stator or rotor component is a stator component which comprises a center part, a generally cylindrical body around the center part, and a series of said vanes spaced around the center part and extending radially from the center part to the cylindrical body.  
   
   
       19 . A process according to  claim 18  wherein the preformed inserts extend the length of the vanes in a radial direction and include an enlarged end at either end of the preformed inserts, which enlarged ends are surrounded by the material of the balance of the stator during casting of the product.  
   
   
       20 . A process according to  claim 19  including the steps of positioning the preformed inserts in a mould base, positioning one or more core insert parts of the mould in association with the mould base and so as to hold or assist in holding the preformed inserts in position, and fitting a mould top part to the mould.  
   
   
       21 . A process according to  claim 20  including positioning the preformed inserts in the mould base by fitting the preformed inserts into one or more recesses in the mould base.  
   
   
       22 . A stator or rotor including a number of radially extending vanes or blades, the leading portions of which are formed by preformed inserts about which a trailing portion of each of the vanes or blades and the balance of stator or rotor have been cast, the preformed inserts being formed of a stronger or more wear-resistant material than the material from which the trailing portions of the vanes or blades and balance of the stator or rotor has been cast.  
   
   
       23 . A stator or rotor according to  claim 22  wherein the preformed inserts are formed from stainless steel.  
   
   
       24 . A stator or rotor according to  claim 23  wherein the balance of the stator or rotor is cast from a metal selected from the group consisting of aluminum, an aluminum alloy, magnesium, and a magnesium alloy.  
   
   
       25 . A stator according to  claim 24  which comprises a center part, a generally cylindrical body around the center part, and a series of said vanes spaced around the center part and extending radially from the center part to the cylindrical body.  
   
   
       26 . A stator according to  claim 22  wherein the preformed inserts extend the length of the vanes in a radial direction and include an enlarged end at either end of the preformed inserts which enlarged ends are surrounded by the material of the balance of the stator during casting of the product.