Liquid metal directional casting apparatus

Abstract

An apparatus for directionally casting articles generally includes a seal between a mold assembly and chill plate. In one embodiment, the mold assembly includes a skirt laterally extending from at least one shell mold, wherein the skirt includes a channel disposed in a bottom surface that is configured to surround the at least one shell mold. A chill plate fastened to a bottom of the mold assembly and includes a boss having a shape complementary to the channel, wherein the boss of the chill plate is seated within the channel of the mold assembly to define the seal about the at least one shell mold.

1 . An apparatus for directionally casting an article, the apparatus comprising:
 a mold assembly comprising an opening for receiving molten metal, at least one shell mold in fluid communication with the opening, and a skirt laterally extending from the at least one shell mold, wherein the skirt comprises a selected one of a channel and a boss disposed in a bottom surface that is configured to surround the at least one shell mold; and   a chill plate comprising the other of the selected one of the channel and the boss having a complementary shape such that the boss is seated within the channel to define a seal about the at least one shell mold when the mold assembly is attached to the chill plate.   
   
   
       2 . The apparatus of  claim 1 , further comprising a ring abutting an interior side of the boss and seated within the channel when the chill plate and mold assembly are fastened together. 
   
   
       3 . The apparatus of  claim 1 , further comprising a ring abutting an exterior side of the boss and seated within the channel when the chill plate and mold assembly are fastened together. 
   
   
       4 . The apparatus of  claim 1 , further comprising two rings abutting each sidewall of the boss and seated within the channel when the chill plate and mold assembly are fastened together. 
   
   
       5 . The apparatus of  claim 1 , wherein the ring is dimensioned such that the ring compresses upon fastening of the mold assembly and the chill plate. 
   
   
       6 . The apparatus of  claim 2 , further comprising a paste disposed on the ring. 
   
   
       7 . The apparatus of  claim 2 , wherein the ring is formed of a metal. 
   
   
       8 . The apparatus of  claim 2 , wherein the ring is formed of a cloth. 
   
   
       9 . The apparatus of  claim 2 , wherein the ring is formed of alumina, alumina-silica, alumina-boria-silica, graphite, silicon carbide, carbon, copper, aluminum, and combinations thereof. 
   
   
       10 . The apparatus of  claim 2 , wherein the ring is formed of a ceramic. 
   
   
       11 . An apparatus for directionally casting an article, the apparatus comprising:
 a mold assembly comprising an opening for receiving molten metal, at least one shell mold in fluid communication with the opening, and a skirt laterally extending from the at least one shell mold, wherein the skirt comprises a channel disposed in a bottom surface that is configured to surround the at least one shell mold;   a chill plate fastened to the mold assembly, the chill plate comprising a channel complementary to the channel of the mold assembly; and   a sealing member disposed within the channels of the chill plate and the mold assembly to define a seal between the mold assembly and the chill plate.   
   
   
       12 . The apparatus of  claim 11 , wherein the seal member is dimensioned such that the sealing member compresses upon fastening of the mold assembly and the chill plate. 
   
   
       13 . The apparatus of  claim 11 , wherein the sealing member is disposed about the at least one shell mold. 
   
   
       14 . The apparatus of  claim 11 , wherein the sealing member is formed of a metal. 
   
   
       15 . The apparatus of  claim 11 , wherein the sealing member is formed of a cloth. 
   
   
       16 . The apparatus of  claim 11 , wherein the seal member is formed of a ceramic. 
   
   
       17 . An apparatus for directionally casting an article, comprising:
 a mold assembly comprising at least one shell mold in fluid communication with an opening for receiving molten metal, and a skirt laterally extending from the at least one shell mold, wherein the skirt comprises a channel disposed in a bottom surface that is configured to surround the at least one shell mold;   a chill plate fastened to the mold assembly, the chill plate comprising a substantially planar surface, and a support post configured to effect lowering of the mold assembly;   a sealing member disposed within the channel between the mold assembly and the chill plate; and   a liquid metal cooling bath positioned below the chill plate maintained at a temperature below a solidus temperature of the molten metal.   
   
   
       18 . The apparatus of  claim 17 , further comprising a paste disposed on the sealing member. 
   
   
       19 . The apparatus of  claim 18 , wherein the sealing member is dimensioned such that the sealing member compresses upon fastening of the mold assembly and the chill plate. 
   
   
       20 . The apparatus of  claim 18 , wherein the sealing member is formed of a ceramic or a metal.