Hybrid casting process for structural castings

Abstract

A hybrid casting process for structural components uses a re-usable metallic mold rather than a sand mold to produce more consistent cast components. The hybrid casting process uses a metallic mold coupled to a core mold to produce the near net shape of the cast component. Machining operations are performed on the near net shape cast component to produce a final component that meets tolerances and other specifications of the structural component.

1 . A casting assembly for producing a structural component, the casting assembly comprising:
 a metallic mold comprising:
 walls defining surfaces of the structural component; 
   a heating device coupled to the metallic mold, wherein the heating device is configured to increase the temperature of surfaces of the metallic mold by:
 heating a first portion of the metallic mold during the solidifying of the metallic material within the metallic mold; and 
 heating a second portion of the metallic mold during the solidifying of the metallic material within the metallic mold; and 
   a cooling device coupled to the metallic mold, wherein the cooling device is configured to decrease the temperature of surfaces of the metallic mold by:
 cooling a third portion of the metallic mold during the solidifying of the metallic material within the metallic mold; and 
 cooling a fourth portion of the metallic mold during the solidifying of the metallic material within the metallic mold; and 
   a core positioned within the walls of the metallic mold.   
     
     
         2 . The casting assembly of  claim 1 , wherein the heating device and cooling device are fluid channels positioned within the walls the metallic mold, and wherein the heating device is configured to flow hot fluid through the fluid channels to heat the metallic mold and the cooling device is configured to flow cold fluid through the fluid channels to cool the metallic mold. 
     
     
         3 . The casting assembly of  claim 1 , wherein the metallic mold is constructed from one or more of a steel, titanium, copper, and tungsten. 
     
     
         4 . The casting assembly of  claim 1 , wherein:
 the core is a ceramic core constructed from a ceramic material;   the core is utilized to produce one or more internal passages and internal features within the structural component; and   the core is removed from the structural component by breaking the core into pieces and shaking the core from an interior of the structural component.   
     
     
         5 . The casting assembly of  claim 1 , wherein:
 the first portion of the metallic mold is on an exterior surface of the metallic mold;   the second portion of the metallic mold is on an interior surface of the metallic mold;   the third portion of the metallic mold is on an exterior surface of the metallic mold; and   the fourth portion of the metallic mold is on an interior surface of the metallic mold.   
     
     
         6 . The casting assembly of  claim 1 , wherein a resistance heating element is coupled to walls of the metallic mold. 
     
     
         7 . The casting assembly of  claim 1 , wherein the metallic mold is shaped to conform to external surfaces of the structural component. 
     
     
         8 . The casting assembly of  claim 1 , wherein the metallic mold is a generally cube or box shaped mold. 
     
     
         9 . The casting assembly of  claim 1 , wherein the metallic mold is constructed from one or more of a cast iron, alloy steel, nickel alloy, copper alloy, and tungsten alloy. 
     
     
         10 . The casting assembly of  claim 1 , wherein the metallic material is one or more of an aluminum alloy and a magnesium alloy. 
     
     
         11 . The casting assembly of  claim 1 , wherein the metallic mold has a higher temperature melting point than the metallic material poured into the metallic mold.