Precision casting process

Abstract

A ceramic casting vessel ( 92 ) including an insert ( 94 ) extending between a shell ( 91 ) and a core ( 93 ) of the vessel to define a cooling channel of an alloy component cast therein. The insert may include a portion ( 96 ) running generally parallel to a surface of the shell to define a cooling channel running generally parallel to a surface of the component. Ends of the insert may be disposed in respective grooves ( 95, 97 ) formed in the shell and/or core.

The invention claimed is: 
     
         1 . A casting vessel for alloy component casting, the casting vessel comprising:
 a shell defining an interior volume;   a core disposed within the interior volume; and   an insert disposed between the shell and core, the insert comprising:
 a first end abutting the shell; 
 a second end abutting the core; and 
 a non-linear portion disposed between the first and second ends; 
   wherein the non-linear portion defines a geometry of a non-linear cooling channel of an alloy component cast in the casting vessel.   
     
     
         2 . The casting vessel of  claim 1 , wherein the insert comprises a comb design defining geometries of a plurality of cooling channels. 
     
     
         3 . The casting vessel of  claim 1 , wherein the insert further comprises a portion between the first and second ends extending generally parallel to a proximate surface of the shell such that the cooling channel comprises a portion running generally parallel to a surface of the alloy component. 
     
     
         4 . The casting vessel of  claim 3 , wherein the insert comprises a comb design defining geometries of a plurality of cooling channels, each cooling channel comprising a portion extending generally parallel to a proximate surface of the shell. 
     
     
         5 . The casting vessel of  claim 1 , wherein at least one of the first and second ends of the insert is disposed within a mating groove formed in the shell or core respectively. 
     
     
         6 . The casting vessel of  claim 1 , wherein one of the first and second ends of the insert is formed to be integral to the shell or core, and a second of the first and second ends of the insert is disposed within a mating groove formed in the core or shell respectively. 
     
     
         7 . The casting vessel of  claim 1 , wherein the non-linear portion of the insert comprises a first linear section adjoining a second linear section at an angle. 
     
     
         8 . An alloy component cast in the casting vessel of  claim 1 . 
     
     
         9 . A casting vessel for alloy component casting, the casting vessel comprising:
 a shell;   a core disposed within the shell; and   an insert comprising a first end abutting the shell and a second end abutting the core;   wherein at least one of the first and second ends of the insert is disposed within a mating groove formed in the shell or core respectively.   
     
     
         10 . The casting vessel of  claim 9 , wherein the insert further comprises a non-linear portion extending between the first and second ends. 
     
     
         11 . The casting vessel of  claim 10 , wherein the non-linear portion of the insert comprises a first linear section adjoining a second linear section at an angle. 
     
     
         12 . The casting vessel of  claim 9 , wherein the insert comprises a comb design. 
     
     
         13 . The casting vessel of  claim 9 , wherein the insert further comprises a portion between the first and second ends extending generally parallel to a proximate surface of the shell such that an alloy component cast in the casting vessel comprises a cooling channel comprising a portion running generally parallel to a surface of the alloy component. 
     
     
         14 . An alloy component cast in the casting vessel of  claim 13 .