Bondcasting process using investment and sand casting

Abstract

A method of forming a component having a plurality of parts constructed from at least two different materials includes forming a first part made from a first material, placing a sandcasting pattern in a sand molding box, filling the sand molding box with sand, removing the sandcasting pattern from the sand molding box, placing the first part in a first portion of a void in the sand with the void formed by the removal of the sandcasting pattern, filling a remaining area of the void with a second material, and allowing the second material to solidify to form a second part.

1 . A method of manufacturing an apparatus comprising:
 providing a first sub-component having a locking feature, the first sub-component being constructed from a superalloy;   placing the first sub-component into a void in sand in a sand molding box, the void having a first portion shaped like the first sub-component and a second portion shaped like a second sub-component with the first sub-component sitting in the void such that the locking feature is adjoining the second portion and the second portion is unoccupied by the first sub-component;   introducing a second material in a fluidic state into the second portion so that the second material is adjacent to at least a part of the locking feature; and   solidifying the second material to form the second sub-component adjoining the locking feature.   
     
     
         2 . The method of  claim 1 , the step of placing the first sub-component into the void in the sand casting mold comprising:
 molding part of the first portion of the void and part of the second portion of the void in a first sand molding box through the use of a first pattern;   placing at least a part of the first sub-component into the part of the first portion of the void;   molding a remaining part of the first portion of the void and a remaining part of the second portion of the void in a second sand molding box through the use of a second pattern; and   placing the second sand molding box adjacent to the first sand molding box.   
     
     
         3 . The method of  claim 2 , wherein the part of the first portion in the first sand molding box and the remaining part of the first portion in the second sand molding box form the void that has the same dimensions as the first sub-component such that when at least a part of the first sub-component is placed into the part of the first portion of the first half of the sand molding box the sand in the first half of the sand molding box is undisturbed and when the remaining part of the first portion in the second half of the sand molding box is placed adjacent to the first half of the sand molding box the sand in the second half of the sand molding box is undisturbed. 
     
     
         4 . The method of  claim 1 , wherein the first sub-component is made up of a plurality of pieces with each piece being similarly shaped and unattached to other pieces of the first component. 
     
     
         5 . The method of  claim 4 , further comprising:
 aligning the plurality of pieces in the first portion of the void.   
     
     
         6 . The method of  claim 4 , wherein the second sub-component has an annular shape and the plurality of pieces of the first sub-component are arranged radially within the second sub-component. 
     
     
         7 . The method of  claim 1 , wherein the locking feature is a projection that extends into the second portion such that the second sub-component solidifies around the locking feature. 
     
     
         8 . The method of  claim 1 , wherein the first sub-component includes at least one hollow feature. 
     
     
         9 . The method of  claim 1 , wherein the melting temperature of the first material is higher than the melting temperature of the second material. 
     
     
         10 . The method of  claim 1 , wherein the first component is constructed using investment casting. 
     
     
         11 . The method of  claim 1 , further comprising:
 performing final finishing on the first sub-component and the second sub-component.   
     
     
         12 . A method of making an apparatus constructed from at least two different materials, the method comprising:
 investment casting a first sub-component constructed from a first material, the first sub-component having a locking feature;   placing a first pattern in sand to create a first sand casting mold;   placing a second pattern in sand to create a second sand casting mold;   removing the first pattern and the second pattern;   positioning the first sub-component in a first impression in the first sand casting mold, the first impression being sized to house at least a portion of the first sub-component, the first sub-component being positioned so that the locking feature is adjoining a second impression in the first sand casting mold that has the same dimensions as at least a portion of a second sub-component;   assembling the first sand casting mold and the second sand casting mold so that the first sub-component is within a first cavity having the same dimensions as the first sub-component and a second cavity having the same dimensions as the second sub-component is formed adjacent to the locking feature;   introducing a second material in a fluidic state into the second cavity to form the second sub-component; and   allowing the second material to solidify within the second cavity adjoining the locking feature.   
     
     
         13 . The method of  claim 12 , further comprising:
 removing the first sand casting mold and the second sand casting mold from around the first sub-component and the second sub-component.   
     
     
         14 . The method of  claim 12 , wherein the second sub-component solidifies around the locking feature. 
     
     
         15 . The method of  claim 12 , wherein the first sub-component includes at least one hollow feature. 
     
     
         16 . A method of forming a component having a plurality of parts constructed from at least two different materials, the method comprising:
 forming a first part made from a first material;   placing a sandcasting pattern in a sand molding box;   filling the sand molding box with sand;   removing the sandcasting pattern from the sand molding box;   placing the first part in a first portion of a void in the sand, the void formed by the removal of the sandcasting pattern;   filling a remaining area of the void with a second material; and   allowing the second material to solidify to form a second part.   
     
     
         17 . The method of  claim 11 , further comprising:
 forming a third part made from a third material; and   placing the third part in a second portion of the void in the sand.   
     
     
         18 . The method of  claim 17 , wherein the first part and the third part are formed using investment casting. 
     
     
         19 . The method of  claim 16 , wherein the first part is a plurality of similarly shaped pieces. 
     
     
         20 . The method of  claim 16 , wherein the first part is made from a high temperature alloy.