Methods and Systems for Investment Casting

Abstract

Methods and systems for investment casting with high performance aluminum alloys are described. High performance aluminum alloys can be modified with nanoparticles to be compatible with investment casting processes.

What is claimed is: 
     
         1 . A metal alloy for investment casting, comprising:
 an aluminum alloy selected from the group consisting of: a 2xx series aluminum alloy, a 2xxx series aluminum alloy, a 6xxx series aluminum alloy, and a 7xxx series aluminum alloy; and   at least one type of nanoparticle dispersed in the aluminum alloy;   wherein the metal alloy is compatible with an investment casting process.   
     
     
         2 . The metal alloy of  claim 1 , wherein the metal alloy is selected from the group consisting of A201, AA2024, AA2219, A206, AA2618, AA5083, AA6013, AA6061, AA6063, AA6069, AA6110A, AA7034, AA7050, AA7075, and AA7068. 
     
     
         3 . The metal alloy of  claim 1 , wherein the at least one type of nanoparticle is selected from the group consisting of a metal oxide, a non-metal oxide, a metal carbide, a non-metal carbide, a metal silicide, a metal boride, a metal nitride, and any combinations thereof. 
     
     
         4 . The metal alloy of  claim 1 , wherein the at least one type of nanoparticle has a core-shell structure. 
     
     
         5 . The metal alloy of  claim 1 , wherein the at least one type of nanoparticle comprises less than or equal to 30 vol. % of the metal alloy. 
     
     
         6 . The metal alloy of  claim 1 , wherein the at least one type of nanoparticle comprises 0.1 vol. % to 2 vol. % of the metal alloy. 
     
     
         7 . The metal alloy of  claim 1 , wherein the metal alloy is configured to investment cast a part with at least one thickness of greater than or equal to 0.2 mm. 
     
     
         8 . A method for investment casting comprising:
 melting an aluminum alloy modified with at least one type of nanoparticle;   filling an investment casting mold with the molten aluminum alloy with the at least one type of nanoparticle; and   cooling the mold to solidify the molten aluminum alloy to form a part.   
     
     
         9 . The method of  claim 8  further comprising, anodizing the part with at least one color. 
     
     
         10 . The method of  claim 8 , wherein the aluminum alloy is selected from the group consisting of: a 2xx series aluminum alloy, a 2xxx series aluminum alloy, a 6xxx series aluminum alloy, and a 7xxx series aluminum alloy. 
     
     
         11 . The method of  claim 8 , wherein the aluminum alloy is selected from the group consisting of: A201, AA2024, AA2219, A206, AA2618, AA5083, AA6013, AA6061, AA6063, AA6069, AA6110A, AA7034, AA7050, AA7075, and AA7068. 
     
     
         12 . The method of  claim 8 , wherein the at least one type of nanoparticle comprises a material selected from the group consisting of: a metal oxide, a non-metal oxide, a metal carbide, a non-metal carbide, a metal silicide, a metal boride, a metal nitride, and any combinations thereof. 
     
     
         13 . The method of  claim 8 , wherein the at least one type of nanoparticle has a core-shell structure. 
     
     
         14 . The method of  claim 8 , wherein the at least one type of nanoparticle comprises less than or equal to 30 vol. % of the aluminum alloy. 
     
     
         15 . The method of  claim 8 , wherein the at least one type of nanoparticle comprises 0.1 vol. % to 2 vol. % of the aluminum alloy. 
     
     
         16 . The method of  claim 8 , wherein the part has at least one section with a thickness of greater than or equal to 0.2 mm. 
     
     
         17 . An investment cast metal part comprising:
 an aluminum alloy; and   at least one type of nanoparticle;   wherein the at least one type of nanoparticle is distributed in the aluminum alloy; and   wherein the aluminum alloy is selected from the group consisting of a 2xx series aluminum alloy, a 2xxx series aluminum alloy, a 6xxx series aluminum alloy, and a 7xxx series aluminum alloy.   
     
     
         18 . The metal part of  claim 17 , wherein the aluminum alloy is selected from the group consisting of A201, AA2024, AA2219, A206, AA2618, AA5083, AA6013, AA6061, AA6063, AA6069, AA6110A, AA7034, AA7050, AA7075, and AA7068. 
     
     
         19 . The metal part of  claim 17 , wherein the at least one type of nanoparticle comprises a material selected from the group consisting of: a metal oxide, a non-metal oxide, a metal carbide, a non-metal carbide, a metal silicide, a metal boride, a metal nitride, and any combinations thereof. 
     
     
         20 . The metal part of  claim 17 , wherein the at least one type of nanoparticle has a core-shell structure. 
     
     
         21 . The metal part of  claim 17 , wherein the nanoparticle comprises less than or equal to 30 vol. % of the aluminum alloy. 
     
     
         22 . The metal part of  claim 17 , wherein the nanoparticle comprises 0.1 vol. % to 2 vol. % of the aluminum alloy. 
     
     
         23 . The metal part of  claim 17 , wherein the metal part is configured to be anodized with at least one color. 
     
     
         24 . The metal part of  claim 17 , wherein the metal part has at least one section with a thickness of greater than or equal to 0.2 mm.