Casting process and articles for performing same

Details Casting process and articles for performing same Casting process and articles for performing same

2003-02-25

2008-12-09

Kerns, Kevin P (Department: 1793)

Metal founding

Process

Shaping liquid metal against a forming surface

Reexamination Certificate

active

07461684

ABSTRACT:
A method for producing a cast article comprises using a porous powder article as a sacrificial pattern. The porous powder article is preferably made using a rapid prototyping process. The porous powder article is used as a sacrificial pattern for a mold into which a molten metal is cast. Some embodiments include a step of proving the porous powder article with a ceramic coating. Methods of making molds and patterns using a porous powder article are also disclosed. The powder comprising the porous powder article may be a metal, ceramic or cermet. In some embodiments, the powder alloys with the molten casting metal. In some other embodiments, the powder and the casting metal form a composite. Sacrificial casting mold patterns comprising porous powder articles and casting molds comprising such sacrificial patterns are also disclosed.

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