Device and method for additive casting of metallic parts

Abstract

A method and an apparatus for additive casting of parts is disclosed. The method may include: depositing, on a build table, a first portion of a mold, such that, the depositing may be performed layer by layer; pouring liquid substance into the first portion of the mold to form a first casted layer; solidifying at least a portion of the first casted layer; depositing a second portion of the mold, on top of the first portion of the mold; pouring the liquid substance into the second portion of the mold to form a second casted layer, on top of at least a portion of the first casted layer; and solidifying at least a portion of the second casted layer. The method may further include joining the first and second casted layers prior to the pouring of a third casted layer.

What is claimed is: 
     
         1 . A method of additive casting of parts, comprising:
 depositing, on a build table, a first portion of a mold, wherein the depositing is performed layer by layer;   pouring a molten metal into the first portion of the mold to form a first casted layer;   solidifying at least a portion of the first casted layer;   depositing a second portion of the mold, on top of the first portion of the mold;   pouring the molten metal into the second portion of the mold to form a second casted layer, on top of at least a portion of the first casted layer; and   solidifying at least a portion of the second casted layer.   
     
     
         2 . The method of  claim 1 , further comprising: receiving a three-dimensional (3D) part model comprising one or more parts, the part model is divided into a plurality of casted layers. 
     
     
         3 . The method of  claim 1 , further comprising:
 joining the first and second casted layers prior to the pouring of a third casted layer.   
     
     
         4 . The method of  claim 3 , wherein joining comprises melting at least a portion of the interface between the first and second casted layers. 
     
     
         5 . The method of  claim 3 , wherein joining comprises treating at least a portion of an upper surface of the second casted layer with at least one of: an induction heater, a resistance welder, an ultrasonic welder, plasma deposition unit, E-beam, a laser, a welding arc, a torch, cold fusion and magnetic field flow. 
     
     
         6 . The method of  claim 1 , further comprising: pre-heating each casted layer prior to the pouring of an additional casted layer. 
     
     
         7 . The method of  claim 1 , further comprising: providing surface treatment to each casted layer after solidification and prior to the pouring of an additional casted layer. 
     
     
         8 . The method of  claim 1 , further comprising: providing surface treatment to internal walls of each mold portion prior to the pouring of the corresponding casted layer. 
     
     
         9 . The method of  claim 1 , further comprising leveling the first casted layer and the first mold portion to be in the same level prior to the deposition of the second mold portion. 
     
     
         10 . The method of claim, wherein the depositing and pouring steps are performed under a protective atmosphere. 
     
     
         11 . The method of  claim 1 , wherein each mold layer comprises a mixture of granular material and a binder, wherein the granular material may include at least one of: ceramic powders, sand, clay, and any combination thereof. 
     
     
         12 . The method of  claim 1 , wherein:
 the first casted layer is casted by pouring a first molten metal having a first chemical composition; and the second casted layer is casted by pouring a second molten metal having a second chemical composition.   
     
     
         13 . The method of  claim 1 , wherein pouring the molten metal into the second mold portion is in an amount sufficient to form the second casted layer and to compensate for at least one of: shrinkage of the first casted layer and thickness deviation in the first casted layer. 
     
     
         14 . An additive casting apparatus comprising: a movable dispensing unit in fluid connection with a first container containing mold material, the dispensing unit comprising one or more liquid introduction ports for depositing the mold material;
 a movable pouring unit in fluid connection with at least one second container for holding a molten metal, the pouring unit comprising one or more liquid introduction ports for pouring at least one molten metal;   a build table for holding the deposited mold material and the poured molten metal; and
 a controller configured to: 
 control the movable dispensing unit to deposit a first portion of a mold, layer by layer; 
 control the movable pouring unit to pour at least one liquid substance into the first portion of the mold to form a first casted layer; 
 control the movable dispensing unit to deposit a first portion of a mold, layer by layer, on top of the first portion; and 
 control the movable pouring unit to pour the at least one molten metal into the second portion of the mold to form a second casted layer on top of at least a portion of the first casted layer. 
   
     
     
         15 . The additive casting apparatus of  claim 14 , further comprising:
 a joining unit configured to join the first and second casted layers prior to a deposition of a third mold portion and the pouring of a third casted layer.   
     
     
         16 . The additive casting apparatus of  claim 15 , wherein the joining unit is at least one of: an induction heater, E-beam, a resistance welder, an arc welder, a laser welder, a torch, a gluing device, a cold fusion unit, a magnet for magnetic field flow, an ultrasonic bonding unit and a heater for diffusion bonding. 
     
     
         17 . The additive casting apparatus of  claim 14 , wherein the at least one second container is a crucible and the liquid substance is one of: a molten metal and molten glass. 
     
     
         18 . The additive casting apparatus of  claim 14 , further comprising a pre-heating unit for heating each casted layer prior to pouring an additional casted layer. 
     
     
         19 . The additive casting apparatus of  claim 14 , further comprising:
 one or more surface treatment units for treating the surface of each casted layer after the solidification and prior to pouring an additional casted layer.   
     
     
         20 . The additive casting apparatus of  claim 14 , further comprising:
 an enclosure filled with protective atmosphere for providing the protective atmosphere to the casted layers during casting.