Method for Forming Casting Molds

Abstract

Disclosed herein are methods for forming casting molds. In one embodiment, a method for forming a mold comprises casting a mold having a cavity surface, forming surface features on the cavity surface, wherein the surface features comprise a mixture, and heat treating the mixture. In another embodiment an article is disclosed.

1 . A method for forming a mold comprising:
 casting a mold having a cavity surface;   forming surface features on the cavity surface, wherein the surface features comprise a mixture;   heat treating the mixture.   
     
     
         2 . The method of  claim 1 , further comprising extruding the mixture through the nozzle of an apparatus. 
     
     
         3 . The method of  claim 2 , further comprising, controlling the motion of the nozzle and a flow rate at which the mixture is extruded through the nozzle. 
     
     
         4 . The method of  claim 1 , wherein the surface features are selected from the group consisting of patterns, drops, smears, layers, lines, shapes, and combinations comprising at least one of the foregoing. 
     
     
         5 . The method of  claim 1 , wherein the mixture is selected from the group consisting of metals, ceramics, and combinations comprising at least one of the foregoing. 
     
     
         6 . The method of  claim 5 , wherein the mixture is a slurry. 
     
     
         7 . The method of  claim 1  wherein the heat treating process attains a temperature that is sufficient to sinter the mixture. 
     
     
         8 . The method of  claim 1 , wherein the heat treating process employs an energy source selected from the group consisting of a focused energy source, a broad heat source, and combinations comprising at least one of the foregoing. 
     
     
         9 . The method of  claim 8 , wherein the focused energy source is selected from the group consisting of a plasma, a microwave, a laser, an electron beam, and combinations comprising at least one of the foregoing. 
     
     
         10 . The method of  claim 1 , further comprises sintering the mold at a temperature of about 1,000° C. to about 2,200° C. 
     
     
         11 . The method of  claim 1 , further comprising conducting a secondary operation to the mold, wherein the secondary operation is selected from the group consisting of an inspection process, a coating process, a machining process, a labeling process, a fixturing process, a modification process, and combinations comprising at least one of the foregoing. 
     
     
         12 . A method for forming a mold comprising:
 forming a die;   casting a mold within the die using a ceramic composition and a casting process selected from the group consisting of investment casting, slip casting, gel casting, sand casting, plaster casting, die-casting, injection molding, slurry injection, powder forming (compaction), reaction forming, colloidal forming, cold isostatic pressing, hot isostatic pressing, and combinations comprising at least one of the foregoing;   heating the mold;   extruding a mixture onto a cavity surface of the mold to form surface features thereon, wherein the mixture is extruded through the nozzle of an apparatus; and,   heat treating the mixture.   
     
     
         13 . The method of  claim 12 , further comprising, controlling the motion of the nozzle and a flow rate at which the mixture is extruded through the nozzle. 
     
     
         14 . The method of  claim 12 , wherein the surface features are selected from the group consisting of patterns, drops, smears, layers, lines, shapes, and combinations comprising at least one of the foregoing. 
     
     
         15 . The method of  claim 12 , wherein the mixture is selected from the group consisting of metals, ceramics, and combinations comprising at least one of the foregoing. 
     
     
         16 . The method of  claim 12 , wherein the mixture is a slurry. 
     
     
         17 . The method of  claim 12  wherein the heat treating process attains a temperature that is sufficient to sinter the mixture. 
     
     
         18 . The method of  claim 12 , wherein the heat treating process employs an energy source selected from the group consisting of a focused energy source, a broad heat source, and combinations comprising at least one of the foregoing. 
     
     
         19 . The method of  claim 18 , wherein the focused energy source is selected from the group consisting of a plasma, a microwave, a laser, an electron beam, and combinations comprising at least one of the foregoing. 
     
     
         20 . The method of  claim 12 , wherein the ceramic composition comprises a ceramic powder. 
     
     
         21 . The method of  claim 12 , wherein the ceramic composition is a slurry. 
     
     
         22 . The method of  claim 12 , further comprises sintering the mold at a temperature of about 1,000° C. to about 2,200° C. 
     
     
         23 . The method of  claim 12 , further comprising conducting a secondary operation to the mold, wherein the secondary operation is selected from the group consisting of an inspection process, a coating process, a machining process, a labeling process, a fixturing process, a modification process, and combinations comprising at least one of the foregoing. 
     
     
         24 . An article formed by the method of  claim 1 . 
     
     
         25 . An article formed by the method of  claim 12 .