Refractory mold and method of making

Abstract

A refractory mold is disclosed. The refractory mold includes a fugitive pattern assembly comprising a hollow sprue that comprises a sprue wall disposed about a longitudinal axis; a pattern disposed outwardly of the sprue wall; and an outwardly extending gate attached to and extending between the sprue wall and the pattern, the hollow sprue, pattern and gate each formed from a fugitive material; and a refractory mold formed on and having a mold cavity defined by an outer surface of the fugitive pattern assembly.

What is claimed is: 
     
       1. A refractory mold, comprising:
 a fugitive pattern assembly comprising a hollow sprue that comprises a sprue wall disposed about a longitudinal axis; a plurality of patterns disposed outwardly of the sprue wall; and a plurality of outwardly extending gates attached to and extending between the sprue wall and the pattern, the hollow sprue comprising a plurality of horizontally joined individual pattern segments, wherein the horizontally joined individual pattern segments are not stacked on top of each other, each pattern segment comprising an axially-extending pattern section of the sprue wall, a pattern spaced away from the pattern section of the sprue wall, and a gate attached to and extending between the pattern and the pattern section of the sprue wall, the pattern sections of the sprue wall joined to form the assembly, the hollow sprue, patterns and gates each formed from a fugitive material; and 
 a refractory mold formed on and having a mold cavity defined by an outer surface of the fugitive pattern assembly including the hollow sprue portion comprising joined pattern segments. 
 
     
     
       2. The refractory mold of  claim 1 , wherein the fugitive pattern assembly further comprises a runner disposed proximate an end, and wherein the refractory mold is also formed on an outer surface of the runner and comprises a runner portion of the mold cavity. 
     
     
       3. The refractory mold of  claim 2  A refractory mold, comprising:
 a fugitive pattern assembly comprising a hollow sprue that comprises a sprue wall disposed about a longitudinal axis; a plurality of patterns disposed outwardly of the sprue wall; and a plurality of outwardly extending gates attached to and extending between the sprue wall and the pattern, the hollow sprue comprising a plurality of vertically joined individual pattern segments, each pattern segment comprising an axially-extending pattern section of the sprue wall, a pattern spaced away from the pattern section of the sprue wall, and a gate attached to and extending between the pattern and the pattern section of the sprue wall, the pattern sections of the sprue wall joined to form the assembly, the hollow sprue, patterns and gates each formed from a fugitive material; and 
 a refractory mold formed on and having a mold cavity defined by an outer surface of the fugitive pattern assembly including the hollow sprue portion comprising joined pattern segments, 
 wherein the fugitive pattern assembly further comprises a runner disposed proximate an end, and wherein the refractory mold is also formed on an outer surface of the runner and comprises a runner portion of the mold cavity, 
 wherein the runner is disposed within and attached to an inner surface of the sprue wall. 
 
     
     
       4. The refractory mold of  claim 2 , wherein the runner is disposed proximate a lower end of the sprue wall. 
     
     
       5. The refractory mold of  claim 2  A refractory mold, comprising:
 a fugitive pattern assembly comprising a hollow sprue that comprises a sprue wall disposed about a longitudinal axis; a plurality of patterns disposed outwardly of the sprue wall; and a plurality of outwardly extending gates attached to and extending between the sprue wall and the pattern, the hollow sprue comprising a plurality of vertically joined individual pattern segments, each pattern segment comprising an axially-extending pattern section of the sprue wall, a pattern spaced away from the pattern section of the sprue wall, and a gate attached to and extending between the pattern and the pattern section of the sprue wall, the pattern sections of the sprue wall joined to form the assembly, the hollow sprue, patterns and gates each formed from a fugitive material; and 
 a refractory mold formed on and having a mold cavity defined by an outer surface of the fugitive pattern assembly including the hollow sprue portion comprising joined pattern segments, 
 wherein the fugitive pattern assembly further comprises a runner disposed proximate an end, and wherein the refractory mold is also formed on an outer surface of the runner and comprises a runner portion of the mold cavity, 
 wherein the runner comprises a plurality of outwardly extending spokes, each spoke attached to an inner surface of the sprue wall. 
 
     
     
       6. The refractory mold of  claim 2 , wherein the hollow sprue comprises a hollow cylindrical sprue. 
     
     
       7. The refractory mold of  claim 2 , wherein the pattern comprises a plurality of patterns disposed about the outer surface of the hollow sprue. 
     
     
       8. The refractory mold of  claim 2  A refractory mold, comprising:
 a fugitive pattern assembly comprising a hollow sprue that comprises a sprue wall disposed about a longitudinal axis; a plurality of patterns disposed outwardly of the sprue wall; and a plurality of outwardly extending gates attached to and extending between the sprue wall and the pattern, the hollow sprue comprising a plurality of vertically joined individual pattern segments, each pattern segment comprising an axially-extending pattern section of the sprue wall, a pattern spaced away from the pattern section of the sprue wall, and a gate attached to and extending between the pattern and the pattern section of the sprue wall, the pattern sections of the sprue wall joined to form the assembly, the hollow sprue, patterns and gates each formed from a fugitive material; and 
 a refractory mold formed on and having a mold cavity defined by an outer surface of the fugitive pattern assembly including the hollow sprue portion comprising joined pattern segments, 
 wherein the fugitive pattern assembly further comprises a runner disposed proximate an end, and wherein the refractory mold is also formed on an outer surface of the runner and comprises a runner portion of the mold cavity, 
 wherein the pattern assembly further comprises: 
 a second pattern disposed inwardly of the sprue wall; and 
 an inwardly extending second gate attached to and extending between the sprue wall and the second pattern, the second pattern and second gate each also formed from a second fugitive material, and wherein the refractory mold is also formed on an outer surface of the second pattern and the second gate and comprises a second portion of the mold cavity. 
 
     
     
       9. The refractory mold of  claim 1 , wherein the fugitive material comprises a wax, polymer, metal, ceramic, clay, wood, or inorganic material, or a combination thereof. 
     
     
       10. The refractory mold of  claim 1 , wherein the refractory mold comprises a mold wall comprising a plurality of layers of a dried refractory slurry. 
     
     
       11. The refractory mold of  claim 10 , wherein the dried refractory slurry comprises zircon, fused silica, silica, an alumino silicate aluminosilicate, mullite or fused alumina, or a combination thereof. 
     
     
       12. The refractory mold of  claim 10 , wherein the mold wall has a thickness of less than about 0.12 inches. 
     
     
       13. The refractory mold of  claim 10 , wherein the mold wall is gas permeable. 
     
     
       14. A method of making a refractory mold, comprising:
 forming a fugitive pattern assembly comprising a hollow sprue that comprises a sprue wall disposed about a longitudinal axis; a pattern disposed outwardly of the sprue wall; and a an outwardly extending gate attached to and extending between an outer surface of the sprue wall and the pattern, the hollow sprue comprising a plurality of horizontally joined individual pattern segments, wherein the horizontally joined individual pattern segments are not stacked on top of each other, each pattern segment comprising an axially-extending or peripherally-extending pattern section of the sprue wall, a pattern spaced away from the pattern section of the sprue wall, and a gate attached to and extending between the pattern and the pattern section of the sprue wall, the pattern sections of the sprue wall joined to form the assembly, the hollow sprue, pattern and gate each formed from a fugitive material; and 
 depositing a refractory mold on an outer surface of the fugitive pattern assembly, the refractory mold having a mold cavity defined by the outer surface of the fugitive pattern assembly including the hollow sprue portion comprising joined pattern segments. 
 
     
     
       15. The method of  claim 14 , further comprising heating the refractory mold to remove the fugitive pattern assembly or sinter the refractory mold, or a combination thereof. 
     
     
       16. The method of  claim 14 , wherein forming the pattern assembly further comprises A method of making a refractory mold, comprising:
 forming a fugitive pattern assembly comprising a hollow sprue that comprises a sprue wall disposed about a longitudinal axis; a pattern disposed outwardly of the sprue wall; and an outwardly extending gate attached to and extending between an outer surface of the sprue wall and the pattern, the hollow sprue comprising a plurality of horizontally joined individual pattern segments, each pattern segment comprising an axially-extending pattern section of the sprue wall, a pattern spaced away from the pattern section of the sprue wall, and a gate attached to and extending between the pattern and the pattern section of the sprue wall, the pattern sections of the sprue wall joined to form the assembly, the hollow sprue pattern and gate each formed from a fugitive material; 
 
       depositing a refractory mold on an outer surface of the fugitive pattern assembly, the refractory mold having a mold cavity defined by the outer surface of the fugitive pattern assembly including the hollow sprue portion comprising joined pattern segments;
 forming a runner from a fugitive material; and 
 joining the runner proximate an end of the hollow sprue, the runner disposed about the longitudinal axis and joined to the sprue wall. 
 
     
     
       17. The method of  claim 14 , wherein depositing the refractory mold comprises forming a plurality of layers of a refractory material. 
     
     
       18. The method of  claim 17 , wherein forming a plurality of layers of a refractory material comprises:
 dipping the fugitive pattern assembly in a slurry comprising a refractory material to form a slurry layer; and 
 drying the slurry to form a dried slurry layer. 
 
     
     
       19. The method of  claim 18 , further comprising repeating dipping and drying to form a plurality of slurry layers. 
     
     
       20. The method of  claim 18 , wherein the refractory material comprises zircon, fused silica, silica, an alumino silicate aluminosilicate, mullite, or fused alumina, or a combination thereof. 
     
     
       21. The method of  claim 18 , wherein the slurry is selected to provide a gas permeable refractory mold. 
     
     
       22. The method of  claim 14 , wherein the pattern segments are formed by 3D printing. 
     
     
       23. A refractory mold, comprising:
 a fugitive pattern assembly comprising a hollow sprue that comprises a sprue wall disposed about a longitudinal axis; a plurality of patterns disposed outwardly of the sprue wall; and a plurality of outwardly extending gates attached to and extending between the sprue wall and the pattern, the hollow sprue comprising a plurality of joined individual pattern segments, each pattern segment comprising an axially-extending or a peripherally-extending pattern section of the sprue wall, a pattern spaced away from the pattern section of the sprue wall, and a gate attached to and extending between the pattern and the pattern section of the sprue wall, the pattern sections of the sprue wall joined to form the assembly, the hollow sprue, pattern and gate each formed from a fugitive material; 
 a runner joined to proximate an end of the hollow sprue, the runner disposed about the longitudinal axis and joined to the sprue wall; and 
 a refractory mold formed on and having a mold cavity defined by an outer surface of the fugitive pattern assembly including the hollow sprue portion comprising joined pattern segments. 
 
     
     
       24. The refractory mold of  claim 23 , wherein the pattern segments are formed by 3D printing.