US2015174653A1PendingUtilityA1

System and methods for removing core elements of cast components

67
Individually held — no corporate assignee on recordPriority: Dec 19, 2013Filed: Dec 16, 2014Published: Jun 25, 2015
Est. expiryDec 19, 2033(~7.4 yrs left)· nominal 20-yr term from priority
Inventors:Carl R. VernerJohn Joseph Marcin
B22D 29/002B22D 30/00B22D 29/006B22D 29/00B22D 29/003
67
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Claims

Abstract

A system and methods are provided for removing core elements of cast components. In one embodiment, a method includes controlling a first high temperature autoclave cycle for a cast component in a vessel with a first solution concentration to remove at least a first portion of core elements, wherein the first solution concentration, temperature and pressure in the vessel are controlled to expose one or more casting pins in the cast component. The method may also include controlling a second high temperature autoclave cycle for the cast component in the vessel with second solution concentration, wherein the second solution concentration, temperature and pressure in the vessel during the second high temperature autoclave cycle are controlled to loosen one or more of the casting pins from the cast component, and controlling one or more low temperature autoclave cycles to remove core and casting pins from the cast component.

Claims

exact text as granted — not AI-modified
What is claimed is: 
     
         1 . A method for removing core elements of cast components, the method comprising:
 controlling a first high temperature autoclave cycle for a cast component in a vessel with a first solution concentration to remove at least a first portion of core elements, wherein the first solution concentration, temperature and pressure in the vessel are controlled to expose one or more casting pins in the cast component;   controlling a second high temperature autoclave cycle for the cast component in the vessel with second solution concentration, wherein the second solution concentration, temperature and pressure in the vessel during the second high temperature autoclave cycle are controlled to loosen one or more of the casting pins from the cast component; and   controlling one or more low temperature autoclave cycles following the second high temperature cycle to remove core and casting pins from the cast component.   
     
     
         2 . The method of  claim 1 , wherein the first high temperature autoclave cycle includes heating the vessel to a temperature within the range of 95 to 200 degrees Celsius (C). 
     
     
         3 . The method of  claim 1 , wherein the solution of the first high temperature autoclave cycle is solution of less than 40% of KOH or less than 40% of NaOH. 
     
     
         4 . The method of  claim 1 , wherein the second high temperature autoclave cycle includes heating the vessel to a temperature within the range of 200 to 315 degrees Celsius (C). 
     
     
         5 . The method of  claim 1 , wherein the solution of the second high temperature autoclave cycle is solution of at least 40% of KOH or at least 40% of NaOH. 
     
     
         6 . The method of  claim 1 , wherein each high temperature autoclave cycle includes a cooling cycle that is controlled to cycled on and off multiple times during each autoclave cycle to provide repetitive and rapid pressure changes in the vessel, promote agitation, and promote a flushing action in the solution. 
     
     
         7 . The method of  claim 1 , wherein 3-5 low temperature autoclave cycles are initiated in the vessel. 
     
     
         8 . The method of  claim 1 , wherein the autoclave cycles are controlled to remove core elements including ceramic cores and alumina casting pins. 
     
     
         9 . The method of  claim 1 , wherein the autoclave cycles are initiated in a vessel having a volume within the range of 3.7 to 189 liters. 
     
     
         10 . The method of  claim 1 , wherein the each autoclave cycle includes flushing the cast component with a fluid to remove one or more of core and casting pin material. 
     
     
         11 . A system for removing core elements of cast components comprising:
 a vessel;   a controller configured to control solution concentration, temperature and pressure in the vessel, wherein the controller is configured to
 control a first high temperature autoclave cycle for a cast component in the vessel with a first solution concentration to remove at least a first portion of core elements, wherein the first solution concentration, temperature and pressure in the vessel are controlled to expose one or more casting pins in the cast component; 
 control a second high temperature autoclave cycle for the cast component in the vessel with second solution concentration, wherein the second solution concentration, temperature and pressure in the vessel during the second high temperature autoclave cycle are controlled to loosen one or more of the casting pins from the cast component; and 
 control one or more low temperature autoclave cycles following the second high temperature cycle to remove core and casting pins from the cast component. 
   
     
     
         12 . The system of  claim 11 , wherein the first high temperature autoclave cycle includes heating the vessel to a temperature within the range of 95 to 200 degrees Celsius (C). 
     
     
         13 . The system of  claim 11 , wherein the solution of the first high temperature autoclave cycle is solution of less than 40% of KOH or less than 40% of NaOH. 
     
     
         14 . The system of  claim 11 , wherein the second high temperature autoclave cycle includes heating the vessel to a temperature within the range of 200 to 315 degrees Celsius (C). 
     
     
         15 . The system of  claim 11 , wherein the solution of the second high temperature autoclave cycle is solution of at least 40% of KOH or at least 40% of NaOH. 
     
     
         16 . The system of  claim 11 , further comprising cooling coils, wherein the controller controls the cooling coils to be cycled on and off multiple times during each autoclave cycle to provide repetitive and rapid pressure changes in the vessel, promote agitation, and promote a flushing action in the solution. 
     
     
         17 . The system of  claim 11 , wherein 3-5 low temperature autoclave cycles are initiated in the vessel. 
     
     
         18 . The system of  claim 11 , wherein the autoclave cycles are controlled to remove core elements including ceramic cores and alumina casting pins. 
     
     
         19 . The system of  claim 11 , wherein the autoclave cycles are initiated in a vessel having a volume within the range of 3.7 to 189 liters. 
     
     
         20 . The system of  claim 11 , wherein the each autoclave cycle includes flushing the cast component with a fluid to remove one or more of core and casting pin material.

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