Rapid casting article manufacturing

Abstract

A method of manufacturing a casting article for use in a casting process includes rapidly forming the casting article out of a metallic material. A ceramic coating is applied to an exterior surface of the casting article.

1 . A method of manufacturing a casting article for use in a casting process, comprising:
 (a) rapidly forming the casting article out of a metallic material; and   (b) applying a ceramic coating to an exterior surface of the casting article.   
     
     
         2 . The method as recited in  claim 1 , wherein the casting article is a core. 
     
     
         3 . The method as recited in  claim 1 , wherein the casting article is a shell. 
     
     
         4 . The method as recited in  claim 1 , comprising the step of;
 (c) creating a 3D model of the casting article prior to the step of rapidly forming the casting article.   
     
     
         5 . The method as recited in  claim 4 , wherein said step (a) comprises:
 forming the casting article using the 3D model.   
     
     
         6 . The method as recited in  claim 1 , wherein said step (a) comprises:
 forming the casting article additively layer by layer.   
     
     
         7 . The method as recited in  claim 1 , wherein said step (a) comprises:
 forming the casting article using a metal deposition process.   
     
     
         8 . The method as recited in  claim 1 , wherein said step (b) comprises:
 applying the ceramic coating using a deposition process.   
     
     
         9 . The method as recited in  claim 1 , wherein said step (b) comprises:
 applying the ceramic coating using a spray process.   
     
     
         10 . The method as recited in  claim 1 , comprising the step of:
 (c) using the casting article in a casting process to cast a part.   
     
     
         11 . A method of manufacturing a casting article for use in a casting process, comprising:
 (a) forming a first metallic layer;   (b) adding a second metallic layer onto the first metallic layer;   (c) adding additional metallic layers onto the second metallic layer to render a net-shaped casting article; and   (d) applying a coating to an exterior surface of the net-shaped casting article.   
     
     
         12 . The method as recited in  claim 11 , comprising the step of:
 (e) using the net-shaped casting article in a casting process to cast a part.   
     
     
         13 . The method as recited in  claim 11 , wherein the first metallic layer, the second metallic layer and the additional metallic layers are formed layer by layer using a metal deposition process. 
     
     
         14 . The method as recited in  claim 11 , wherein said step (d) comprises:
 applying the ceramic coating using a deposition process.   
     
     
         15 . The method as recited in  claim 11 , wherein said step (d) comprises:
 applying the ceramic coating using a spray process.   
     
     
         16 . The method as recited in  claim 11 , Wherein said step (a) includes:
 forming a melt pool on top of a substrate; and   injecting a metallic powder into the melt pool to form the first metallic layer of the casting article.   
     
     
         17 .- 19 . (canceled) 
     
     
         20 . The method as recited in  claim 7 , wherein the metal deposition process includes using a metal deposition system having a substrate and a melting device. 
     
     
         21 . The method as recited in  claim 20 , wherein the melting device melts an ingot of the metallic material to create a melt pool on top of the substrate and then a metallic powder is injected into the melt pool to form a first layer of the casting article. 
     
     
         22 . The method as recited in  claim 21 , wherein a 3D model that provides the numerical data for manufacturing the casting article is communicated to the metal deposition system prior to melting the ingot of the metallic material and injecting the metallic powder. 
     
     
         23 . The method as recited in  claim 1 , wherein the metallic material includes at least one of a refractory metal and a superalloy.