Method for manufacturing a pattern for a hollow component

Abstract

A pattern with internal cores for creating a hollow component is composed of a first pattern half having one or more first self-locating features; a second pattern half having one or more second self-locating features; and one or more cores disposed in contact with the one or more first self-locating features and the one or more second self-locating features. The method for its manufacture includes the steps of creating a first pattern half having one or more first self-locating features; creating a second pattern half having one or more second self-locating features; providing one or more cores; and assembling the pattern by engaging the one or more first self-locating features and the one or more second self-locating features about the one or more cores.

1 . A method for manufacturing a hollow component using a wax pattern with internal cores, comprising: 
 creating a first pattern half having one or more first self-locating features;    creating a second pattern half having one or more second self-locating features;    creating one or more cores prior to assembling the pattern; and    assembling the pattern by engaging said one or more first self-locating features and said one or more second self-locating features about said one or more cores.    
   
   
       2 . The method of  claim 1 , wherein assembling comprises engaging complimentarily said one or more first self-locating features with each of said one or more second self-locating features.  
   
   
       3 . The method of  claim 1 , wherein providing comprises providing one or more refractory metal cores.  
   
   
       4 . The method of  claim 1 , wherein providing comprises providing one or more ceramic cores.  
   
   
       5 . The method of  claim 1 , wherein assembling comprises: 
 aligning said one or more first self-locating features with said one or more cores;    aligning said one or more second self-locating features with said one or more cores;    aligning said first pattern half and said second half; and    disposing said first pattern half in contact with said one or more cores and said second pattern half.    
   
   
       6 . The method of  claim 1 , further comprising the steps of: 
 welding said first pattern half and said second pattern half about said one or more cores; and    blending a weld seam formed by welding.    
   
   
       7 . The method of  claim 6 , wherein welding comprising wax welding.  
   
   
       8 . The method of  claim 6 , wherein blending comprises blending said weld seam to seal one or more core exits and a parting surface formed between said first pattern half and said second pattern half.  
   
   
       9 . The method of  claim 1 , wherein assembling comprises disposing said one or more cores at an angle within said one or more first self-locating features and said one or more second self-locating features.  
   
   
       10 . The method of  claim 1 , wherein assembling comprises disposing said one or more cores within said one or more first self-locating features and said one or more second self-locating features through a side portion of said first pattern half and said second pattern half.  
   
   
       11 . A pattern with internal cores for creating a hollow component, comprising: 
 a first pattern half having one or more first self-locating features;    a second pattern half having one or more second self-locating features; and    one or more cores disposed in contact with said one or more first self-locating features and said one or more second self-locating features.    
   
   
       12 . The pattern of  claim 11 , wherein said one or more first self-locating features are either negative or positive features and said one or more second self-locating features compliment said one or more first self-locating features.  
   
   
       13 . The pattern of  claim 11 , further comprising one or more additional pattern pieces disposed in contact with either said first pattern half, said second pattern half or both.  
   
   
       14 . The pattern of  claim 11 , wherein said one or more cores are disposed at an angle to said first pattern half and said second pattern half.  
   
   
       15 . The pattern of  claim 11 , wherein said one or more cores are located within a side portion of said first pattern half and said second pattern half.  
   
   
       16 . The pattern of  claim 11 , wherein said first pattern half and said second pattern half comprise a wax material.  
   
   
       17 . The pattern of  claim 11 , wherein said one or more cores comprise a ceramic material.  
   
   
       18 . The pattern of  claim 11 , wherein said one or more cores comprise a refractory metal.