Electromagnetically stirred sand castings

Abstract

A casting system, mold, and method are disclosed for electromagnetically stirring sand castings. In an embodiment, the casting mold includes a mold body having a cavity therein, and a passageway fluidly connecting the cavity with an exterior of the mold body. The passageway allows for introduction of a molten metal into the cavity. The mold body further includes at least one induction coil embedded in a cope of the mold body; and at least one induction coil embedded in a drag of the mold body. The induction coils are configured to generate an electromagnetic field for stirring a molten metal casting while it solidifies inside the mold.

1 . A mold comprising a mold body having a cavity therein, the mold body further comprising:
 a passageway fluidly connecting the cavity with an exterior of the mold body, wherein the passageway allows for introduction of a molten metal into the cavity,   wherein the cavity has an irregular three-dimensional shape in the form of a turbine component;   at least one induction coil embedded in a cope of the mold body; and   at least one induction coil embedded in a drag of the mold body,   wherein the at least one induction coil embedded in the cope of the mold body, and the at least one induction coil embedded in the drag of the mold body further include a round or a rectangular cross sectional shape, and a cross-sectional diameter of about 30 mm.   
     
     
         2 . The mold of  claim 1 , wherein the mold body further comprises sand. 
     
     
         3 . The mold of  claim 1 , wherein the molten metal further comprises one of steel, a ferrous metal, or a nonferrous, conductive metal. 
     
     
         4 . The mold of  claim 1 , wherein the at least one induction coil embedded in the cope of the mold body and the at least one induction coil embedded in the drag of the mold body are fluid-cooled. 
     
     
         5 . The mold of  claim 4 , wherein the cooling fluid further comprises deionized water. 
     
     
         6 . The mold of  claim 1 , wherein the at least one induction coil embedded in the cope of the mold body, and the at least one induction coil embedded in the drag of the mold body further include copper, wherein the copper is coated with a ceramic. 
     
     
         7 . The mold of  claim 1 , wherein the at least one induction coil embedded in the cope of the mold body and the at least one induction coil embedded in the drag of the mold body operate at a frequency of between about 20 Hz and about 10 kHz. 
     
     
         8 . The mold of  claim 1 , wherein the at least one induction coil embedded in the cope of the mold body and the at least one induction coil embedded in the drag of the mold body are configured to generate an electromagnetic field for stirring the molten metal during solidification of the molten metal. 
     
     
         9 . (canceled) 
     
     
         10 . A casting system comprising:
 a mold body including:
 a cavity therein, wherein the cavity has an irregular three-dimensional shape in the form of a turbine component; 
 a passageway fluidly connecting the cavity with an exterior of the mold body, wherein the passageway allows for introduction of a molten metal into the cavity; and 
 at least one fluid-cooled induction coil embedded in a cope of the mold body and at least one fluid-cooled induction coil embedded in a drag of the mold body, 
 wherein the at least one fluid-cooled induction coil embedded in a cope of the mold body and the at least one fluid-cooled induction coil embedded in a drag of the mold body are configured to generate an electromagnetic field for stirring the molten metal during solidification of the molten metal, 
 wherein the at least one induction coil embedded in the cope of the mold body, and the at least one induction coil embedded in the drag of the mold body further include a round or a rectangular cross sectional shape, and a cross-sectional diameter of about 30 mm. 
   
     
     
         11 . The casting system of  claim 10 , wherein the mold body further comprises sand. 
     
     
         12 . The casting system of  claim 10 , wherein the molten metal further comprises one of steel, a ferrous metal, or a nonferrous, conductive metal. 
     
     
         13 . The casting system of  claim 10 , wherein the at least one induction coil embedded in the cope of the mold body, and the at least one induction coil embedded in the drag of the mold body further include copper, wherein the copper is coated with a ceramic. 
     
     
         14 . The casting system of  claim 10 , wherein the cooling fluid further comprises deionized water. 
     
     
         15 . The casting system of  claim 10 , wherein the at least one induction coil embedded in the cope of the mold body and the at least one induction coil embedded in the drag of the mold body operate at a frequency of between about 20 Hz and about 10 kHz. 
     
     
         16 - 20 . (canceled)