CPC B28B 1/001 (2013.01) [B22C 9/06 (2013.01); B28B 11/243 (2013.01); B28B 17/0081 (2013.01); B33Y 10/00 (2014.12); B33Y 40/20 (2020.01); B33Y 50/02 (2014.12); B33Y 80/00 (2014.12)] | 14 Claims |
1. A method for casting a component, the method comprising:
identifying a location of a unitary core-shell mold that is susceptible to a stress concentration by forecasting a stress magnitude approaching a load limit of a shell wall or a core wall during casting;
receiving data indicative of the location of the unitary core-shell mold that is susceptible to the stress concentration when the unitary core-shell mold is employed to cast the component;
forming, via an additive manufacturing process, the unitary core-shell mold defining a casting cavity, the unitary core-shell mold comprising the shell wall defining an outer component shape and the core wall positioned inward of the shell wall and defining an inner component shape, wherein the shell wall or the core wall defines a reinforcement recess adjacent to the location that is susceptible to the stress concentration;
following the forming of the unitary core-shell mold, positioning a support member within the reinforcement recess and adjacent with the location and engaging the support member with a first retention feature in the reinforcement recess, wherein the first retention feature in the reinforcement recess is in a shape of the reinforcement recess creating a friction fit with the support member, is a protrusion or recess within the reinforcement recess shaped to engage a corresponding recess or protrusion of the support member, or includes an adhesive within the reinforcement recess; and
casting the component within the casting cavity.
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