Casting method and mold design for optimization of material properties of a casting

Abstract

A casting method and mold design for optimization of material properties of a casting is disclosed, wherein the optimization is accomplished through control of a cooling rate of the casting to provide desired material properties throughout the casting.

1 . A casting apparatus ( 60 ) comprising: 
 a first mold pattern ( 62 ) for forming a first mold cavity for receiving a molten material therein, and    a second mold pattern ( 64 ) positioned adjacent at least a portion of said first mold pattern ( 62 ), said second mold pattern ( 64 ) forming a second mold cavity for receiving the molten material therein, wherein the molten material in the second mold cavity controls a cooling rate of the molten material in the portion of the first mold cavity.    
   
   
       2 . The apparatus of  claim 1 , wherein said first mold pattern ( 62 ) and said second mold pattern ( 64 ) are patterns for a sand casting process.  
   
   
       3 . The apparatus ( 60 ) of  claim 1 , wherein said first mold pattern ( 62 ) and said second mold pattern ( 64 ) are patterns for a die casting process.  
   
   
       4 . The apparatus ( 60 ) of  claim 1 , wherein said first mold pattern ( 62 ) and said second mold pattern ( 64 ) are patterns for an investment casting process.  
   
   
       5 . The apparatus ( 60 ) of  claim 1 , wherein said first mold pattern ( 62 ) and said second mold pattern ( 64 ) are patterns for a permanent mold casting process.  
   
   
       6 . The apparatus ( 60 ) of  claim 1 , wherein said second mold pattern ( 64 ) is adjacent at least one side of said first mold pattern ( 62 ).  
   
   
       7 . The apparatus ( 60 ) of  claim 6 , wherein said second mold pattern ( 64 ) is adjacent two sides of said first mold pattern ( 62 ).  
   
   
       8 . The apparatus ( 60 ) of  claim 6 , wherein said second mold pattern ( 64 ) is adjacent three sides of said first mold pattern ( 62 ).  
   
   
       9 . The apparatus ( 60 ) of  claim 1 , wherein said second mold pattern ( 64 ) surrounds at least a portion of said first mold pattern ( 62 ).  
   
   
       10 . A mold ( 60 ) for casting comprising: 
 a mold ( 62 ,  64 ) having a first mold cavity and a second mold cavity formed therein and adapted to receive a molten material, the second mold cavity formed adjacent at least a portion of the first mold cavity,    wherein the molten material received in the second mold cavity controls a cooling rate of the molten material received in the portion of the first mold cavity adjacent the second mold cavity.    
   
   
       11 . The mold ( 60 ) of  claim 10 , wherein said mold ( 62 ,  64 ) is a sand casting mold.  
   
   
       12 . The mold ( 60 ) of  claim 10 , wherein said mold ( 62 ,  64 ) is a die casting mold.  
   
   
       13 . The mold ( 60 ) of  claim 10 , wherein said mold ( 62 ,  64 ) is an investment casting mold.  
   
   
       14 . The mold ( 60 ) of  claim 10 , wherein said mold ( 62 ,  64 ) is a permanent mold casting mold.  
   
   
       15 . The mold ( 60 ) of  claim 10 , wherein the second mold cavity is adjacent one side of the first mold cavity.  
   
   
       16 . The mold ( 60 ) of  claim 15 , wherein the second mold cavity is adjacent two sides of the first mold cavity.  
   
   
       17 . The mold ( 60 ) of  claim 15 , wherein the second mold cavity is adjacent three sides of the first mold cavity.  
   
   
       18 . The mold ( 60 ) of  claim 10 , wherein the second mold cavity surrounds at least a portion of the first mold cavity.  
   
   
       19 . A method ( 110 ) of controlling the cooling rate of molten material in a casting process comprising the steps of: 
 providing a first mold pattern ( 62 ) for forming a first mold cavity for receiving a molten material ( 112 );    providing a second mold pattern ( 64 ) for forming a second mold cavity for receiving a molten material ( 114 );    positioning the second mold pattern ( 64 ) adjacent at least a portion of the first mold pattern ( 62 ), ( 116 ); and    introducing molten material into the first mold cavity and the second mold cavity, wherein the molten material in the second mold cavity controls the cooling rate of the molten material in the portion of the first mold cavity ( 118 ).    
   
   
       20 . The method ( 110 ) of  claim 19 , wherein the second mold pattern ( 64 ) is positioned adjacent at least one side of the first mold pattern ( 62 ).