US 12,168,254 B2
Additively manufactured casting core-shell mold and ceramic shell with variable thermal properties
Xi Yang, Mason, OH (US); Michael Cole, Mason, OH (US); Michael Brown, Dayton, OH (US); Gregory Terrence Garay, West Chester, OH (US); Tingfan Pang, West Chester, OH (US); Brian David Przeslawski, Liberty Township, OH (US); and Douglas Gerard Konitzer, West Chester, OH (US)
Assigned to General Electric Company, Evendale, OH (US)
Filed by General Electric Company, Schenectady, NY (US)
Filed on Oct. 25, 2021, as Appl. No. 17/509,368.
Application 17/509,368 is a division of application No. 15/636,389, filed on Jun. 28, 2017, granted, now 11,173,542.
Prior Publication US 2022/0040754 A1, Feb. 10, 2022
This patent is subject to a terminal disclaimer.
Int. Cl. B22C 9/10 (2006.01); B22C 9/04 (2006.01); B22D 29/00 (2006.01); B28B 1/00 (2006.01); B28B 7/34 (2006.01); B32B 18/00 (2006.01); B33Y 10/00 (2015.01); B33Y 80/00 (2015.01); C04B 35/14 (2006.01)
CPC B22C 9/10 (2013.01) [B22C 9/04 (2013.01); B22D 29/002 (2013.01); B28B 1/001 (2013.01); B28B 7/346 (2013.01); B32B 18/00 (2013.01); B33Y 10/00 (2014.12); B33Y 80/00 (2014.12); C04B 35/14 (2013.01); C04B 2235/6026 (2013.01); C04B 2235/6027 (2013.01); C04B 2237/341 (2013.01); C04B 2237/62 (2013.01)] 11 Claims
OG exemplary drawing
 
1. A method of preparing a cast component using a casting mold, the method comprising:
providing a molten metal into the casting mold, wherein the casting mold comprises:
a core-shell mold formed of a first ceramic material, wherein the core-shell mold includes a shell, a core, a plurality of filaments joining the core to the shell, the plurality of filaments being monolithic with the core and the shell, and at least a first hollow cavity between the core and the shell; and
an outer ceramic layer formed of a second ceramic material, wherein the outer ceramic layer coats at least a portion of the core-shell mold, wherein the outer ceramic layer has at least one different thermal property than the core-shell mold,
wherein each of the plurality of filaments spans between the core and the shell, the plurality of filaments adapted to define a plurality of holes providing fluid communication between the first hollow cavity within the cast component defined by the core and an outer surface of the cast component upon removal of the casting mold.