Multi-piece integrated core-shell structure for making cast component

Abstract

The present disclosure generally relates to partial integrated core-shell investment casting molds that can be assembled into complete molds. Each section of the partial mold may contain both a portion of a core and portion of a shell. Each section can then be assembled into a mold for casting of a metal part. The partial integrated core-shell investment casting molds and the complete molds may be provided with filament structures corresponding to cooling hole patterns on the surface of the turbine blade or the stator vane, which provides a leaching pathway for the core portion after metal casting. The invention also relates to core filaments that can be used to supplement the leaching pathway, for example in a core tip portion of the mold.

1 . A partial ceramic casting mold comprising:
 a first core portion and a first shell portion, the first core portion and first shell portion adapted to interface with at least a second core portion and second shell portion to form a ceramic mold comprising a cavity between the first and second core portions and the first and second shell portions, the cavity adapted to define a cast component upon casting and removal of the ceramic mold.   
     
     
         2 . The partial ceramic casting mold of  claim 1 , wherein the cast component is a turbine blade or a stator vane. 
     
     
         3 . The partial ceramic casting mold of  claim 1 , wherein the first core portion or the first shell portion includes at least one interlocking feature adapted to interface with an interlocking feature on the second core portion or second shell portion. 
     
     
         4 . The partial ceramic casting mold of  claim 3 , wherein the interlocking feature is an interlocking tongue or groove adapted to fasten with a second partial ceramic casting mold. 
     
     
         5 . The partial ceramic casting mold of  claim 3 , wherein the interlocking feature is an interlocking dovetail adapted to fasten with a second partial ceramic casting mold. 
     
     
         6 . The partial ceramic casting mold of  claim 3 , wherein the interlocking feature is a rabbet joint with an interlocking peg adapted to fasten with a second partial ceramic casting mold. 
     
     
         7 . The partial ceramic casting mold of  claim 1 , wherein the first shell portion comprises a pin support or bumper facing the first core portion. 
     
     
         8 . The partial ceramic casting mold of  claim 1 , wherein the first core portion comprises a pin support or bumper facing the first core portion. 
     
     
         9 . The partial ceramic casting mold of  claim 1 , wherein the ceramic mold comprises a plurality of tie structures joining the core portion and shell portion, the tie structures adapted to define a plurality of holes in the cast component upon removal of the mold. 
     
     
         10 . The partial ceramic casting mold of  claim 1 , wherein the cast component is a turbine blade or a stator vane. 
     
     
         11 . A method for fabricating a partial ceramic mold, comprising:
 (a) contacting a cured portion of a workpiece with a liquid ceramic photopolymer;   (b) irradiating a portion of the liquid ceramic photopolymer adjacent to the cured portion through a window contacting the liquid ceramic photopolymer;   (c) removing the workpiece from the uncured liquid ceramic photopolymer; and   (d) repeating steps (a)-(c) until a first shell portion of a partial ceramic mold is formed and optionally a first core portion, the optional first core portion and first shell portion adapted to interface with at least an optional second core portion and second shell portion to form a two piece ceramic mold comprising a cavity between the first and/or second core portions and the first and second shell portions, the cavity adapted to define a cast component upon casting and removal of the ceramic mold.   
     
     
         12 . The method of  claim 11 , wherein the process comprises, after step (d), a step (e) comprising pouring a liquid metal into the two piece ceramic mold and solidifying the liquid metal to form the cast component. 
     
     
         13 . The method of  claim 12 , wherein the process comprises, after step (e), a step (f) comprising removing the two piece ceramic mold from the cast component. 
     
     
         14 . The method of  claim 13 , wherein removing the two piece ceramic mold from the cast component comprises a combination of mechanical force and chemical leaching. 
     
     
         15 . The method of  claim 11 , wherein the first core portion or the first shell portion includes at least one interlocking feature adapted to interface with an interlocking feature on the second core portion or second shell portion. 
     
     
         16 . The method of  claim 11 , wherein the two piece ceramic mold comprises a plurality of tie structures joining the core portion and shell portion, the tie structures adapted to define a plurality of holes in the cast component upon removal of the two piece ceramic mold. 
     
     
         17 . The method of  claim 11 , wherein the cast component is a turbine blade or a stator vane. 
     
     
         18 . The method of  claim 11 , wherein the first shell portion comprises a pin support or bumper facing the first core portion. 
     
     
         19 . The method of  claim 11 , wherein the first core portion comprises a pin support or bumper facing the first core portion. 
     
     
         20 . The method of  claim 11 , wherein the first partial ceramic mold has a first core portion and the second partial ceramic mold has a second core portion. 
     
     
         21 . A method of preparing a cast component using the two piece ceramic mold of  claim 11  comprising:
 pouring a liquid metal into the two piece ceramic casting mold and solidifying the liquid metal to form the cast component; and 
 removing the two piece ceramic mold from the cast component. 
 
     
     
         22 . A method of preparing a cast component comprising:
 assembling a first core portion and a first shell portion of a two piece ceramic mold with at least a second core portion and second shell portion to form a two piece ceramic mold comprising a cavity between the first and second core portions and the first and second shell portions, the cavity adapted to define the shape of the cast component upon casting and removal of the two piece ceramic mold;   pouring a liquid metal into the two piece ceramic casting mold and solidifying the liquid metal to form the cast component; and   removing the two piece ceramic casting mold from the cast component.