Super-alloy and stainless steel casting method

Abstract

Embodiments of the present invention include a method for producing a component that includes melting a super-alloy or stainless steel alloy and transferring the melted alloy to a mold. The mold is mechanically vibrated while the melted alloy solidifies. The component then is removed from the mold.

1 . A method for producing a component comprising:
 melting a stainless steel alloy;   transferring the melted stainless steel alloy to a mold;   mechanically vibrating the mold while the melted stainless steel solidifies to form a component; and   removing the component from the mold.   
     
     
         2 . The method of  claim 1 , wherein the stainless steel alloy is selected from the group consisting of martensitic stainless steel, duplex stainless steel, and austenitic stainless steel. 
     
     
         3 . The method according to  claim 1 , wherein the melting of the stainless steel alloy occurs in an inert atmosphere. 
     
     
         4 . The method according to  claim 1 , wherein the transferring of the melted stainless steel occurs in an inert atmosphere. 
     
     
         5 . The method according to  claim 1 , further comprising applying a coating to the component. 
     
     
         6 . The method according to  claim 5 , wherein the coating comprises a thermal barrier coating or an erosion resistant coating. 
     
     
         7 . The method according to  claim 1 , wherein the vibration comprises a frequency range of from 8 to 60 Hz. 
     
     
         8 . The method according to  claim 1 , wherein the component is selected from the group consisting of a combustion liner, transition piece, buckets, nozzle, blade, vane, and shroud. 
     
     
         9 . A method for producing a component comprising:
 melting a super alloy;   transferring the melted super-alloy to a mold;   mechanically vibrating the mold while the melted stainless steel solidifies to form a component; and   removing the component from the mold.   
     
     
         10 . The method of  claim 9 , wherein the super-alloy is selected from the group consisting of nickel-chromium-iron alloys, nickel-iron-chromium alloys, nickel-iron alloys, and nickel-chromium molybdenum alloys. 
     
     
         11 . The method according to  claim 9 , wherein the melting of the super-alloy comprises an inert atmosphere. 
     
     
         12 . The method according to  claim 9 , wherein the transferring of the melted super-alloy comprises an inert atmosphere. 
     
     
         13 . The method according to  claim 9 , further comprising applying a coating to the component. 
     
     
         14 . The method according to  claim 13 , wherein the coating comprises a thermal barrier coating or an erosion resistant coating. 
     
     
         15 . The method according to  claim 9 , wherein the vibration comprises a frequency range of from 8 to 60 Hz. 
     
     
         16 . The method according to  claim 9 , wherein the component is selected from the group consisting of a combustion liner, transition piece, buckets, nozzle, blade, vane, and shroud.