Method of making a mold

Claim 1

A method of making a mold for a cast product having a plurality of airfoils disposed in a circular array, said method comprising the steps of providing a plurality of airfoil pattern segments formed of a relatively flexible and disposable material, providing a circular pattern member formed of a material having a greater rigidity than material forming the airfoil pattern segments, placing the airfoil pattern segments in a circular array engaging the circular pattern member to form a pattern assembly, said step of placing the airfoil pattern segments in a circular array includes placing the airfoil pattern segments in an array with joints between the airfoil pattern segments free of material interconnecting the airfoil pattern segments so that the airfoil pattern segments can be readily moved relative to each other, connecting the airfoil pattern segments with the circular pattern member to thereby retard movement of the airfoil pattern segments relative to each other and the circular pattern member while maintaining the joints between the airfoil pattern segments free of material interconnecting the airfoil pattern segments, repetitively dipping the pattern assembly in liquid ceramic mold material to form a covering of ceramic mold material overlying at least a portion of the pattern assembly, at least partially supporting the airfoil pattern segments with the relatively rigid circular pattern member during said dipping steps, at least partially drying the covering of ceramic mold material overlying the pattern assembly, disposing of the airfoil pattern segments to expose a circular array of ceramic airfoil mold surfaces having configurations corresponding to the configurations of the airfoil pattern segments, and moving the relatively rigid circular pattern member away from the ceramic airfoil mold surface after performing said step of disposing of the airfoil pattern segments.

Claim 2

A method of making a mold for a cast product having a plurality of airfoils disposed in a circular array, said method comprising the steps of providing a plurality of airfoil pattern segments formed of a relatively flexible and disposable material, providing a circular pattern member formed of a material having a greater rigidity than material forming the airfoil pattern segments, placing the airfoil pattern segments in a circular array engaging the circular pattern member to form a pattern assembly, said step of placing the airfoil pattern segments in a circular array includes placing the airfoil pattern segments in an array with joints between the airfoil pattern segments free of material interconnecting the airfoil pattern segments so that the airfoil pattern segments can be readily moved relative to each other, connecting the airfoil pattern segments with the circular pattern member to thereby retard movement of the airfoil pattern segments relative to each other and the circular pattern member while maintaining the joints between the airfoil pattern segments free of material interconnecting the airfoil pattern segments, repetitively dipping the pattern assembly in liquid ceramic mold material to form a covering of ceramic mold material overlying at least a portion of the pattern assembly, at least partially supporting the airfoil pattern segments with the relatively rigid circular pattern member during said dipping steps, at least partially drying the covering of ceramic mold material overlying the pattern assembly, disposing of the airfoil pattern segments to expose a circular array of ceramic airfoil mold surfaces having configurations corresponding to the configurations of the airfoil pattern segments, and moving the relatively rigid circular pattern member away from the ceramic airfoil mold surface after performing said step of disposing of the airfoil pattern segments.

Claim 6

A method of making a mold for a cast product having a plurality of airfoils disposed in a circular array, said method comprising the steps of providing a plurality of airfoil pattern segments formed of a relatively flexible and disposable material, providing a circular pattern member formed of a material having a greater rigidity than material forming the airfoil pattern segments, placing the airfoil pattern segments in a circular array with radially outer end portions of the airfoil pattern segments engaging the circular pattern member to form a pattern assembly, clamping the radially outer end portion of each of the airfoil pattern segments to the circular pattern member, repetitively dipping the pattern assembly in liquid ceramic mold material to form a covering of ceramic mold material overlying at least a portion of the pattern assembly, retarding relative movement between the airfoil pattern segments during said dipping steps by at least partially supporting the airfoil pattern segments with the relatively rigid circular pattern member, at least partially drying the covering of ceramic mold material overlying the pattern assembly, disposing of the airfoil pattern segments to expose a circular array of ceramic airfoil mold surfaces having configurations corresponding to the configuration of the airfoil pattern segments, and moving the relatively rigid circular pattern member away from the ceramic airfoil mold surfaces.

Claim 7

A method of making a mold for a cast product having a plurality of airfoils disposed in a circular array, said method comprising the steps of providing a plurality of airfoil pattern segments formed of a relatively flexible and disposable material, providing a circular pattern member formed of a material having a greater rigidity than material forming the airfoil pattern segments, placing the airfoil pattern segments in a circular array with radially outer end portions of the airfoil pattern segments engaging the circular pattern member to form a pattern assembly, clamping the radially outer end portion of each of the airfoil pattern segments to the circular pattern member, repetitively dipping the pattern assembly in liquid ceramic mold material to form a covering of ceramic mold material overlying at least a portion of the pattern assembly, retarding relative movement between the airfoil pattern segments during said dipping steps by at least partially supporting the airfoil pattern segments with the relatively rigid circular pattern member, at least partially drying the covering of ceramic mold material overlying the pattern assembly, disposing of the airfoil pattern segments to expose a circular array of ceramic airfoil mold surfaces having configurations corresponding to the configuration of the airfoil pattern segments, and moving the relatively rigid circular pattern member away from the ceramic airfoil mold surfaces.

Claim 11

A method of making a mold for a cast product having a plurality of airfoils disposed in a circular array, said method comprising the steps of providing a plurality of wax airfoil pattern segments, providing a circular metal pattern member, clamping each of the wax airfoil pattern segments to the circular metal pattern member to form a circular array of airfoil pattern segments which are connected with the circular metal pattern member, leaving joints between the wax airfoil pattern segments free of material interconnecting the airfoil pattern segments, applying a covering of liquid ceramic mold material over exposed surface areas of the wax airfoil pattern segments and over at least a portion of the circular metal pattern member while the wax airfoil pattern segments are clamped to the circular metal pattern member, at least partially supporting the wax airfoil pattern segments with the circular metal pattern member during the application of the covering of liquid ceramic mold material to the airfoil pattern segments and to the pattern member, at least partially drying the covering of ceramic mold material overlying the wax airfoil pattern segments and circular metal pattern member, and disposing of the wax airfoil pattern segments while maintaining the circular metal pattern member intact and removing the circular pattern member to expose a circular array of ceramic airfoil mold surfaces having configurations corresponding to the configurations of the wax airfoil pattern segments.

Claim 12

A method of making a mold for a cast product having a plurality of airfoils disposed in a circular array, said method comprising the steps of providing a plurality of wax airfoil pattern segments, providing a circular metal pattern member, clamping each of the wax airfoil pattern segments to the circular metal pattern member to form a circular array of airfoil pattern segments which are connected with the circular metal pattern member, leaving joints between the wax airfoil pattern segments free of material interconnecting the airfoil pattern segments, applying a covering of liquid ceramic mold material over exposed surface areas of the wax airfoil pattern segments and over at least a portion of the circular metal pattern member while the wax airfoil pattern segments are clamped to the circular metal pattern member, at least partially supporting the wax airfoil pattern segments with the circular metal pattern member during the application of the covering of liquid ceramic mold material to the airfoil pattern segments and to the pattern member, at least partially drying the covering of ceramic mold material overlying the wax airfoil pattern segments and circular metal pattern member, and disposing of the wax airfoil pattern segments while maintaining the circular metal pattern member intact and removing the circular pattern member to expose a circular array of ceramic airfoil mold surfaces having configurations corresponding to the configurations of the wax airfoil pattern segments.

Claim 15

A method of making a mold for a cast product having a circular wall portion with a plurality of airfoils disposed in a circular array and extending generally radially from the wall portion, said method comprising the steps of forming a one-piece annular airfoil mold section having a plurality of radially extending airfoil mold cavities with exposed open end portions disposed in a circular array, said step of forming an airfoil mold section including the steps of providing a plurality of airfoil pattern segments, placing the airfoil pattern segments in a circular array, applying a wet coating of liquid ceramic mold material over the airfoil pattern segments, forming a circular discontinuity in the wet coating of ceramic mold material adjacent to end portions of the airfoil pattern segments, at least partially drying the wet coating of ceramic mold material to form a solid covering of ceramic mold material having a circular discontinuity at the location where the circular discontinuity was formed in the wet coating of ceramic mold material, removing the airfoil pattern segments, and separating the covering of ceramic mold material at the circular discontinuity to separate a portion of the covering corresponding to the airfoil mold section from another portion of the covering, forming a one-piece circular mold wall, said step of forming a mold wall including the steps of providing a circular pattern surface, applying a coating of liquid ceramic mold material over the circular pattern surface, at least partially drying the coating of liquid ceramic mold material disposed over the pattern surface, and removing the pattern surface, and positioning the circular mold wall in a coaxial relationship with the annular airfoil mold section with a generally axially extending surface of the circular mold wall spaced apart from and facing the open end portions of the radially extending airfoil mold cavities to at least partially define a product mold cavity.

Claim 16

A method of making a mold for a cast product having a circular wall portion with a plurality of airfoils disposed in a circular array and extending generally radially from the wall portion, said method comprising the steps of forming a one-piece annular airfoil mold section having a plurality of radially extending airfoil mold cavities with exposed open end portions disposed in a circular array, said step of forming an airfoil mold section including the steps of providing a plurality of airfoil pattern segments, placing the airfoil pattern segments in a circular array, applying a wet coating of liquid ceramic mold material over the airfoil pattern segments, forming a circular discontinuity in the wet coating of ceramic mold material adjacent to end portions of the airfoil pattern segments, at least partially drying the wet coating of ceramic mold material to form a solid covering of ceramic mold material having a circular discontinuity at the location where the circular discontinuity was formed in the wet coating of ceramic mold material, removing the airfoil pattern segments, and separating the covering of ceramic mold material at the circular discontinuity to separate a portion of the covering corresponding to the airfoil mold section from another portion of the covering, forming a one-piece circular mold wall, said step of forming a mold wall including the steps of providing a circular pattern surface, applying a coating of liquid ceramic mold material over the circular pattern surface, at least partially drying the coating of liquid ceramic mold material disposed over the pattern surface, and removing the pattern surface, and positioning the circular mold wall in a coaxial relationship with the annular airfoil mold section with a generally axially extending surface of the circular mold wall spaced apart from and facing the open end portions of the radially extending airfoil mold cavities to at least partially define a product mold cavity.

Claim 20

A method of making a mold for a cast product having a plurality of airfoils disposed in a circular array, said method comprising the steps of providing a plurality of disposable airfoil pattern segments, placing the airfoil pattern segments in a circular array with surfaces of the airfoil pattern segments abutting at joints which are free of material interconnecting the airfoil pattern segments, applying a wet coating of liquid ceramic mold material over the circular array of airfoil pattern segments with the joints between airfoil pattern segments free of material interconnecting the airfoil pattern segments, allowing liquid ceramic mold material to flow into at least some of the joints between the airfoil pattern segments while performing said step of applying a coating of liquid ceramic mold material to the circular array of airfoil pattern segments, at least partially drying the ceramic mold material in the joints between the airfoil pattern segments and the ceramic mold material overlying the circular array of airfoil pattern segments, disposing of the airfoil pattern segments to expose a circular array of ceramic mold surfaces having configurations corresponding to the configurations of the airfoil pattern segments and to expose projections of ceramic mold material at locations where the ceramic mold material entered the joints between the airfoil pattern segments, and removing the projections of ceramic mold material at the locations where the ceramic mold material entered the joints between the pattern segments.

Claim 21

A method of making a mold for a cast product having a plurality of airfoils disposed in a circular array, said method comprising the steps of providing a plurality of disposable airfoil pattern segments, placing the airfoil pattern segments in a circular array with surfaces of the airfoil pattern segments abutting at joints which are free of material interconnecting the airfoil pattern segments, applying a wet coating of liquid ceramic mold material over the circular array of airfoil pattern segments with the joints between airfoil pattern segments free of material interconnecting the airfoil pattern segments, allowing liquid ceramic mold material to flow into at least some of the joints between the airfoil pattern segments while performing said step of applying a coating of liquid ceramic mold material to the circular array of airfoil pattern segments, at least partially drying the ceramic mold material in the joints between the airfoil pattern segments and the ceramic mold material overlying the circular array of airfoil pattern segments, disposing of the airfoil pattern segments to expose a circular array of ceramic mold surfaces having configurations corresponding to the configurations of the airfoil pattern segments and to expose projections of ceramic mold material at locations where the ceramic mold material entered the joints between the airfoil pattern segments, and removing the projections of ceramic mold material at the locations where the ceramic mold material entered the joints between the pattern segments.

Claim 25

A method of making a mold for a cast product having a plurality of spaced apart surface areas, said method comprising the steps of providing a plurality of disposable pattern segments formed of a relatively flexible material and having surfaces corresponding to the spaced apart surface areas of the cast product, providing a pattern member formed of a material having a greater rigidity than the material forming the pattern segments, clamping each of the pattern segments to the pattern member with the pattern segments disposed in an array with surfaces of the pattern segments abutting at joints which are free of material interconnecting the pattern segments, applying a wet coating of liquid ceramic mold material over the pattern member and the array of pattern segments with the joints between pattern segments free of material interconnecting the pattern segments and while the pattern segments are clamped to the pattern member, at least partially drying the coating of ceramic mold material overlying the array of pattern segments, disposing of the pattern segments to expose an array of ceramic mold surfaces having configurations corresponding to the configurations of the spaced apart surface areas of the cast product, and moving the pattern member away from the ceramic mold surfaces.

Claim 26

A method of making a mold for a cast product having a plurality of spaced apart surface areas, said method comprising the steps of providing a plurality of disposable pattern segments formed of a relatively flexible material and having surfaces corresponding to the spaced apart surface areas of the cast product, providing a pattern member formed of a material having a greater rigidity than the material forming the pattern segments, clamping each of the pattern segments to the pattern member with the pattern segments disposed in an array with surfaces of the pattern segments abutting at joints which are free of material interconnecting the pattern segments, applying a wet coating of liquid ceramic mold material over the pattern member and the array of pattern segments with the joints between pattern segments free of material interconnecting the pattern segments and while the pattern segments are clamped to the pattern member, at least partially drying the coating of ceramic mold material overlying the array of pattern segments, disposing of the pattern segments to expose an array of ceramic mold surfaces having configurations corresponding to the configurations of the spaced apart surface areas of the cast product, and moving the pattern member away from the ceramic mold surfaces.

Claim 27

A method of making a mold for a cast product having a plurality of spaced apart surface areas, said method comprising the steps of providing a plurality of disposable pattern segments having surfaces corresponding to the spaced apart surface areas of the cast product, placing the pattern segments in an array with surfaces of the pattern segments abutting at joints which are free of material interconnecting the pattern segments, applying a wet coating of liquid ceramic mold material over the array of pattern segments with the joints between pattern segments free of material interconnecting the pattern segments, flowing ceramic mold material into at least some of the joints between the pattern segments while performing said step of applying a coating of liquid ceramic mold material to the array of pattern segments, at least partially drying the coating of ceramic mold material overlying the array of pattern segments, said step of drying the coating of ceramic mold material including the step of at least partially drying the ceramic mold material which enters the joints between the pattern to form projections of ceramic mold material, disposing of the pattern segments to expose an array of ceramic mold surfaces having configurations corresponding to the configurations of the spaced apart surface areas of the cast product, said step of disposing of the pattern segments including the step of leaving the projections of ceramic mold material extending from ceramic mold surfaces at locations where the liquid ceramic mold material entered the joints between the pattern segments, and removing the projections of ceramic mold material from the mold surfaces after having performed said step of disposing of the pattern segments.

Claim 28

A method of making a mold for a cast product having a plurality of spaced apart surface areas, said method comprising the steps of providing a plurality of disposable pattern segments having surfaces corresponding to the spaced apart surface areas of the cast product, placing the pattern segments in an array with surfaces of the pattern segments abutting at joints which are free of material interconnecting the pattern segments, applying a wet coating of liquid ceramic mold material over the array of pattern segments with the joints between pattern segments free of material interconnecting the pattern segments, flowing ceramic mold material into at least some of the joints between the pattern segments while performing said step of applying a coating of liquid ceramic mold material to the array of pattern segments, at least partially drying the coating of ceramic mold material overlying the array of pattern segments, said step of drying the coating of ceramic mold material including the step of at least partially drying the ceramic mold material which enters the joints between the pattern to form projections of ceramic mold material, disposing of the pattern segments to expose an array of ceramic mold surfaces having configurations corresponding to the configurations of the spaced apart surface areas of the cast product, said step of disposing of the pattern segments including the step of leaving the projections of ceramic mold material extending from ceramic mold surfaces at locations where the liquid ceramic mold material entered the joints between the pattern segments, and removing the projections of ceramic mold material from the mold surfaces after having performed said step of disposing of the pattern segments.

Claim 33

A method of making a mold for a cast product having a plurality of airfoils disposed in a circular array, said method comprising the steps of providing a plurality of airfoil pattern segments, providing an annular pattern member, placing at least a portion of each of the airfoil pattern segments in a circular area circumscribed by the pattern member to form a circular array of airfoil pattern segments which are circumscribed by the annular pattern member, said step of placing the airfoil pattern segments in a circular area circumscribed by the pattern member includes the step of positioning the airfoil pattern segments with surfaces in abutting engagement at joints which are free of material interconnecting the airfoil pattern segments, applying a covering of liquid ceramic mold material over exposed surface areas of the airfoil pattern segments and over at least a portion of the annular pattern member, said step of applying a covering of liquid ceramic mold material over the airfoil pattern segments being performed with the joints between airfoil pattern segments free of material interconnecting the airfoil pattern segments, retarding relative movement between airfoil pattern segments with the annular pattern member during the application of the covering of liquid ceramic mold material to the airfoil pattern segments and to the annular pattern member, at least partially drying the covering of ceramic mold material overlying the airfoil pattern segments and annular pattern member, and removing the annular pattern member and airfoil pattern segments to expose a circular mold wall area and to expose a circular array of ceramic airfoil mold surfaces integrally formed with and extending generally inwardly from the mold wall, each of said airfoil mold surfaces having a configuration corresponding to the configuration of an airfoil pattern segment.

Claim 34

A method of making a mold for a cast product having a plurality of airfoils disposed in a circular array, said method comprising the steps of providing a plurality of airfoil pattern segments, providing an annular pattern member, placing at least a portion of each of the airfoil pattern segments in a circular area circumscribed by the pattern member to form a circular array of airfoil pattern segments which are circumscribed by the annular pattern member, said step of placing the airfoil pattern segments in a circular area circumscribed by the pattern member includes the step of positioning the airfoil pattern segments with surfaces in abutting engagement at joints which are free of material interconnecting the airfoil pattern segments, applying a covering of liquid ceramic mold material over exposed surface areas of the airfoil pattern segments and over at least a portion of the annular pattern member, said step of applying a covering of liquid ceramic mold material over the airfoil pattern segments being performed with the joints between airfoil pattern segments free of material interconnecting the airfoil pattern segments, retarding relative movement between airfoil pattern segments with the annular pattern member during the application of the covering of liquid ceramic mold material to the airfoil pattern segments and to the annular pattern member, at least partially drying the covering of ceramic mold material overlying the airfoil pattern segments and annular pattern member, and removing the annular pattern member and airfoil pattern segments to expose a circular mold wall area and to expose a circular array of ceramic airfoil mold surfaces integrally formed with and extending generally inwardly from the mold wall, each of said airfoil mold surfaces having a configuration corresponding to the configuration of an airfoil pattern segment.

Claim 35

A method of making a mold for a cast product having a plurality of airfoils disposed in a circular array, said method comprising the steps of providing a plurality of airfoil pattern segments formed of a relatively flexible and disposable material, providing a circular pattern member formed of a material having a greater rigidity than material forming the airfoil pattern segments, placing the airfoil pattern segments in a circular array engaging the circular pattern member to form a pattern assembly, said step of placing the airfoil pattern segments in a circular array includes positioning the airfoil pattern segments with surfaces in abutting engagement at joints which are free of material interconnecting the airfoil pattern segments, repetitively dipping the pattern assembly in liquid ceramic mold material to form a covering of ceramic mold material overlying at least a portion of the pattern assembly, said step of repetitively dipping the pattern assembly in liquid ceramic mold material including the step of flowing ceramic mold material into at least some of the joints between airfoil pattern segments, retarding relative movement between the airfoil pattern segments during said dipping steps by at least partially supporting the airfoil pattern segments with the relatively rigid circular pattern member, at least partially drying the covering of ceramic mold material overlying the pattern assembly, disposing of the airfoil pattern segments to expose a circular array of ceramic airfoil mold surfaces having configurations corresponding to the configurations of the airfoil pattern segments, said step of disposing of the airfoil pattern segments including the step of leaving projections of ceramic mold material at locations where the liquid ceramic mold material entered the joints betweenn the airfoil pattern segments, moving the relatively rigid circular pattern member away from the ceramic airfoil mold surfaces, and removing the projections of ceramic mold material.

Claim 36

A method of making a mold for a cast product having a plurality of airfoils disposed in a circular array, said method comprising the steps of providing a plurality of airfoil pattern segments formed of a relatively flexible and disposable material, providing a circular pattern member formed of a material having a greater rigidity than material forming the airfoil pattern segments, placing the airfoil pattern segments in a circular array engaging the circular pattern member to form a pattern assembly, said step of placing the airfoil pattern segments in a circular array includes positioning the airfoil pattern segments with surfaces in abutting engagement at joints which are free of material interconnecting the airfoil pattern segments, repetitively dipping the pattern assembly in liquid ceramic mold material to form a covering of ceramic mold material overlying at least a portion of the pattern assembly, said step of repetitively dipping the pattern assembly in liquid ceramic mold material including the step of flowing ceramic mold material into at least some of the joints between airfoil pattern segments, retarding relative movement between the airfoil pattern segments during said dipping steps by at least partially supporting the airfoil pattern segments with the relatively rigid circular pattern member, at least partially drying the covering of ceramic mold material overlying the pattern assembly, disposing of the airfoil pattern segments to expose a circular array of ceramic airfoil mold surfaces having configurations corresponding to the configurations of the airfoil pattern segments, said step of disposing of the airfoil pattern segments including the step of leaving projections of ceramic mold material at locations where the liquid ceramic mold material entered the joints betweenn the airfoil pattern segments, moving the relatively rigid circular pattern member away from the ceramic airfoil mold surfaces, and removing the projections of ceramic mold material.

Claim 40

A method of making a mold for a cast product having a plurality of spaced apart surface areas, said method comprising the steps of providing a plurality of disposable pattern segments formed of a relatively flexible material and having surfaces corresponding to the spaced apart surface areas of the cast product, providing a pattern member formed of a material having a greater ridigity than the material forming the pattern segments, clamping each of the pattern segments to the pattern member with the pattern segments disposed in an array with surfaces of the pattern segments abutting at joints which are free of material interconnecting the pattern segments, said step of clamping each of the pattern segments to the pattern member including providing at least one clamp member and pressing a surface on one of the pattern segments against a surface on the pattern member with the clamp member, applying a wet coating of liquid ceramic mold material over the pattern member and the array of pattern segments with the joints between pattern segments free of material interconnecting the pattern segments and while the pattern segments are clamped to the pattern member, at least partially drying the coating of ceramic mold material overlying the array of pattern segments, disposing of the pattern segments to expose an array of ceramic mold surfaces having configurations corresponding to the configurations of the spaced apart surface areas of the cast product, and moving the pattern member away from the ceramic mold surfaces.

Claim 41

A method of making a mold for a cast product having a plurality of spaced apart surface areas, said method comprising the steps of providing a plurality of disposable pattern segments formed of a relatively flexible material and having surfaces corresponding to the spaced apart surface areas of the cast product, providing a pattern member formed of a material having a greater ridigity than the material forming the pattern segments, clamping each of the pattern segments to the pattern member with the pattern segments disposed in an array with surfaces of the pattern segments abutting at joints which are free of material interconnecting the pattern segments, said step of clamping each of the pattern segments to the pattern member including providing at least one clamp member and pressing a surface on one of the pattern segments against a surface on the pattern member with the clamp member, applying a wet coating of liquid ceramic mold material over the pattern member and the array of pattern segments with the joints between pattern segments free of material interconnecting the pattern segments and while the pattern segments are clamped to the pattern member, at least partially drying the coating of ceramic mold material overlying the array of pattern segments, disposing of the pattern segments to expose an array of ceramic mold surfaces having configurations corresponding to the configurations of the spaced apart surface areas of the cast product, and moving the pattern member away from the ceramic mold surfaces.

Claim 43

A method of making a mold for a cast product having a plurality of airfoils disposed in a circular array, said method comprising the steps of providing a plurality of airfoil pattern segments formed of a relatively flexible and disposable material, providing a circular pattern member formed of a material having a greater rigidity than material forming the airfoil pattern segments, placing the airfoil pattern segments in a circular array with end portions of the airfoil pattern segments engaging the circular pattern member to form a pattern assembly, clamping the end portion of each of the airfoil pattern segments against the circular pattern member, repetitively dipping the pattern assembly in liquid ceramic mold material to form a covering of ceramic mold material overlying at least a portion of the pattern assembly, retarding relative movement between the airfoil pattern segments during said dipping steps by at least partially supporting the airfoil pattern segments with the relatively rigid circular pattern member, at least partially drying the covering of ceramic mold material overlying the pattern assembly, disposing of the airfoil pattern segments to expose a circular array of ceramic airfoil mold surfaces having configurations corresponding to the configurations of the airfoil pattern segments, and moving the relatively rigid circular pattern member away from the ceramic airfoil mold surfaces.

Claim 44

A method of making a mold for a cast product having a plurality of airfoils disposed in a circular array, said method comprising the steps of providing a plurality of airfoil pattern segments formed of a relatively flexible and disposable material, providing a circular pattern member formed of a material having a greater rigidity than material forming the airfoil pattern segments, placing the airfoil pattern segments in a circular array with end portions of the airfoil pattern segments engaging the circular pattern member to form a pattern assembly, clamping the end portion of each of the airfoil pattern segments against the circular pattern member, repetitively dipping the pattern assembly in liquid ceramic mold material to form a covering of ceramic mold material overlying at least a portion of the pattern assembly, retarding relative movement between the airfoil pattern segments during said dipping steps by at least partially supporting the airfoil pattern segments with the relatively rigid circular pattern member, at least partially drying the covering of ceramic mold material overlying the pattern assembly, disposing of the airfoil pattern segments to expose a circular array of ceramic airfoil mold surfaces having configurations corresponding to the configurations of the airfoil pattern segments, and moving the relatively rigid circular pattern member away from the ceramic airfoil mold surfaces.

Claim 45

A method of making a mold for a cast product having a plurality of airfoils disposed in a circular array, said method comprising the steps of providing a plurality of airfoil pattern segments, providing an annular pattern member, placing at least a portion of each of the airfoil pattern segments in a circular area circumscribed by the pattern member, said step of placing the airfoil pattern segments in a circular area circumscribed by the pattern member includes the step of positioning the airfoil pattern segments with surfaces in abutting engagement at joints which are free of material interconnecting the airfoil pattern segments, applying a covering of liquid ceramic mold material over exposed surface areas of the airfoil pattern segments and over at least a portion of the annular pattern member, said step of applying a covering of liquid ceramic mold material over the airfoil pattern segments being performed with the joints between airfoil pattern segments free of material interconnecting the airfoil pattern segments, retarding relative movement between airfoil patterns segments with the annular pattern member during the application of the covering of liquid ceramic mold material to the airfoil pattern segments and to the annular pattern member, at least partially drying the covering of ceramic mold material overlying the airfoil pattern segments and annular pattern member, forming a circular discontinuity in the covering of wet ceramic mold material to at least partially divide the covering of ceramic mold material into portions which can be separated after performing said step of drying the covering of ceramic mold material, and removing the annular pattern member and airfoil pattern segments to expose a circular mold wall area and to expose a circular array of ceramic airfoil mold surfaces integrally formed with and extending generally inwardly from the mold wall, each of said airfoil mold surfaces having a configuration corresponding to the configuration of an airfoil pattern segment.

Claim 46

A method of making a mold for a cast product having a plurality of airfoils disposed in a circular array, said method comprising the steps of providing a plurality of airfoil pattern segments, providing an annular pattern member, placing at least a portion of each of the airfoil pattern segments in a circular area circumscribed by the pattern member, said step of placing the airfoil pattern segments in a circular area circumscribed by the pattern member includes the step of positioning the airfoil pattern segments with surfaces in abutting engagement at joints which are free of material interconnecting the airfoil pattern segments, applying a covering of liquid ceramic mold material over exposed surface areas of the airfoil pattern segments and over at least a portion of the annular pattern member, said step of applying a covering of liquid ceramic mold material over the airfoil pattern segments being performed with the joints between airfoil pattern segments free of material interconnecting the airfoil pattern segments, retarding relative movement between airfoil patterns segments with the annular pattern member during the application of the covering of liquid ceramic mold material to the airfoil pattern segments and to the annular pattern member, at least partially drying the covering of ceramic mold material overlying the airfoil pattern segments and annular pattern member, forming a circular discontinuity in the covering of wet ceramic mold material to at least partially divide the covering of ceramic mold material into portions which can be separated after performing said step of drying the covering of ceramic mold material, and removing the annular pattern member and airfoil pattern segments to expose a circular mold wall area and to expose a circular array of ceramic airfoil mold surfaces integrally formed with and extending generally inwardly from the mold wall, each of said airfoil mold surfaces having a configuration corresponding to the configuration of an airfoil pattern segment.

Claim 47

A method of making a mold for a cast product having a plurality of spaced apart surface areas, said method comprising the steps of providing a plurality of disposable pattern segments formed of a relatively flexible material and having surfaces corresponding to the spaced apart surface areas of the cast product, providing a pattern member formed of a material having a greater rigidity than the material forming the pattern segments, clamping each of the pattern segments to the pattern member with the pattern segments disposed in an array with surfaces of the pattern segments abutting at joints which are free of material interconnecting the pattern segments, applying a wet coating of liquid ceramic mold material over the pattern member and the array of pattern segments with the joints between pattern segments free of material interconnecting the pattern segments and while the pattern segments are clamped to the pattern member, flowing ceramic mold material into at least some of the joints between the pattern segments while performing said step of applying a coating of liquid ceramic mold material to the array of pattern segments, at least partially drying the coating of ceramic mold material overlying the array of pattern segments and the ceramic mold material which enters the joints between the pattern segments, leaving projections of ceramic mold material extending from ceramic mold surfaces at locations where the liquid ceramic mold material entered the joints between the pattern segments, disposing of the pattern segments to expose an array of ceramic mold surfaces having configurations corresponding to the configurations of the spaced apart surface areas of the cast product, moving the pattern member away from the ceramic mold surfaces, and removing the projections of ceramic mold material from the mold surfaces.

Claim 48

A method of making a mold for a cast product having a plurality of spaced apart surface areas, said method comprising the steps of providing a plurality of disposable pattern segments formed of a relatively flexible material and having surfaces corresponding to the spaced apart surface areas of the cast product, providing a pattern member formed of a material having a greater rigidity than the material forming the pattern segments, clamping each of the pattern segments to the pattern member with the pattern segments disposed in an array with surfaces of the pattern segments abutting at joints which are free of material interconnecting the pattern segments, applying a wet coating of liquid ceramic mold material over the pattern member and the array of pattern segments with the joints between pattern segments free of material interconnecting the pattern segments and while the pattern segments are clamped to the pattern member, flowing ceramic mold material into at least some of the joints between the pattern segments while performing said step of applying a coating of liquid ceramic mold material to the array of pattern segments, at least partially drying the coating of ceramic mold material overlying the array of pattern segments and the ceramic mold material which enters the joints between the pattern segments, leaving projections of ceramic mold material extending from ceramic mold surfaces at locations where the liquid ceramic mold material entered the joints between the pattern segments, disposing of the pattern segments to expose an array of ceramic mold surfaces having configurations corresponding to the configurations of the spaced apart surface areas of the cast product, moving the pattern member away from the ceramic mold surfaces, and removing the projections of ceramic mold material from the mold surfaces.

Claim 49

A method of making a mold for a cast product having a plurality of spaced apart surface areas, said method comprising the steps of providing a plurality of disposable pattern segments formed of a relatively flexible material and having surfaces corresponding to the spaced apart surface areas of the cast product, providing a pattern member formed of a material having a greater rigidity than the material forming the pattern segments, clamping each of the pattern segments to the pattern member with the pattern segments disposed in an array with surfaces of the pattern segments abutting at joints which are free of material interconnecting the pattern segments, applying a wet coating of liquid ceramic material over the pattern member and the array of pattern segments with the joints between pattern segments free of material interconnecting the pattern segments and while the pattern segments are clamped to the pattern member, removing at least a major portion of the wet coating of ceramic material overlying a surface area of the pattern member at a location disposed outwardly of the array of pattern segments to separate at least a portion of the coating of wet ceramic material overlying the pattern member from the coating of wet ceramic material overlying the array of pattern segments, at least partially drying the coating of ceramic material overlying the array of pattern segments, disposing of the pattern segments to expose an array of ceramic mold surfaces having configurations corresponding to the configurations of the spaced apart surface areas of the cast product, and moving the pattern member away from the ceramic mold surfaces.

Claim 50

A method of making a mold for a cast product having a plurality of spaced apart surface areas, said method comprising the steps of providing a plurality of disposable pattern segments formed of a relatively flexible material and having surfaces corresponding to the spaced apart surface areas of the cast product, providing a pattern member formed of a material having a greater rigidity than the material forming the pattern segments, clamping each of the pattern segments to the pattern member with the pattern segments disposed in an array with surfaces of the pattern segments abutting at joints which are free of material interconnecting the pattern segments, applying a wet coating of liquid ceramic material over the pattern member and the array of pattern segments with the joints between pattern segments free of material interconnecting the pattern segments and while the pattern segments are clamped to the pattern member, removing at least a major portion of the wet coating of ceramic material overlying a surface area of the pattern member at a location disposed outwardly of the array of pattern segments to separate at least a portion of the coating of wet ceramic material overlying the pattern member from the coating of wet ceramic material overlying the array of pattern segments, at least partially drying the coating of ceramic material overlying the array of pattern segments, disposing of the pattern segments to expose an array of ceramic mold surfaces having configurations corresponding to the configurations of the spaced apart surface areas of the cast product, and moving the pattern member away from the ceramic mold surfaces.

Claim 51

A method of making a mold for a cast product having a plurality of airfoils disposed in a circular array, said method comprising the steps of providing a plurality of airfoil pattern segments formed of a relatively flexible and disposable material, providing a circular support member formed of a material having a greater rigidity than material forming the airfoil pattern segments, placing the airfoil pattern segments in a circular array engaging the circular support member to form a pattern assembly, said step of placing the airfoil pattern segments in a circular array includes placing the airfoil pattern segments in an array with joints between the airfoil pattern segments free of material interconnecting the airfoil pattern segments, clamping the airfoil pattern segments with the circular support member to thereby retard movement of the airfoil pattern segments relative to each other and the circular support member while maintaining the joints between the airfoil pattern segments free of material interconnecting the airfoil pattern segments, repetitively dipping the pattern assembly in liquid ceramic mold material to form a covering of ceramic mold material overlying at least a portion of the pattern assembly, at least partially supporting the airfoil pattern segments with the relatively rigid circular support member during said dipping steps, at least partially drying the covering of ceramic mold material overlying the pattern assembly, and disposing of the airfoil pattern segments to expose a circular array of ceramic airfoil mold surfaces having configurations corresponding to the configurations of the airfoil pattern segments.

Claim 52

A method of making a mold for a cast product having a plurality of airfoils disposed in a circular array, said method comprising the steps of providing a plurality of airfoil pattern segments formed of a relatively flexible and disposable material, providing a circular support member formed of a material having a greater rigidity than material forming the airfoil pattern segments, placing the airfoil pattern segments in a circular array engaging the circular support member to form a pattern assembly, said step of placing the airfoil pattern segments in a circular array includes placing the airfoil pattern segments in an array with joints between the airfoil pattern segments free of material interconnecting the airfoil pattern segments, clamping the airfoil pattern segments with the circular support member to thereby retard movement of the airfoil pattern segments relative to each other and the circular support member while maintaining the joints between the airfoil pattern segments free of material interconnecting the airfoil pattern segments, repetitively dipping the pattern assembly in liquid ceramic mold material to form a covering of ceramic mold material overlying at least a portion of the pattern assembly, at least partially supporting the airfoil pattern segments with the relatively rigid circular support member during said dipping steps, at least partially drying the covering of ceramic mold material overlying the pattern assembly, and disposing of the airfoil pattern segments to expose a circular array of ceramic airfoil mold surfaces having configurations corresponding to the configurations of the airfoil pattern segments.

Claim 54

A method of making a mold for a cast product having a plurality of airfoils disposed in a circular array, said method comprising the steps of providing a plurality of airfoil pattern segments formed of a relatively flexible and disposable material, providing a circular pattern member formed of a material having a greater rigidity than material forming the airfoil pattern segments, placing the airfoil pattern segments in a circular array engaging the circular pattern member to form a pattern assembly, said step of placing the airfoil pattern segments in a circular array includes placing the airfoil pattern segments in an array with joints between the airfoil pattern segments free of material interconnecting the airfoil pattern segments so that the airfoil pattern segments can be readily moved relative to each other, connecting the airfoil pattern segments with the circular pattern member to thereby retard movement of the airfoil pattern segments relative to each other and the circular pattern member while maintaining the joints between the airfoil pattern segments free of material interconnecting the airfoil pattern segments, repetitively dipping the pattern assembly in liquid ceramic mold material to form a covering of ceramic mold material overlying at least a portion of the pattern assembly, said step of dipping the pattern assembly in liquid ceramic mold material including the step of flowing liquid ceramic mold material into at least some of the joints between the airfoil pattern segments, at least partially supporting the airfoil pattern segments with the relatively rigid circular pattern member during said dipping steps, at least partially drying the covering of ceramic mold material overlying the pattern assembly, disposing of the airfoil pattern segments to expose a circular array of ceramic airfoil mold surfaces having configurations corresponding to the configurations of the airfoil pattern segments, moving the relatively rigid circular pattern member away from the ceramic airfoil mold surfaces after performing said step of disposing of the airfoil pattern segments, and removing projections of ceramic mold material at locations where the liquid ceramic mold material entered the joints between the airfoil pattern segments.

Claim 55

A method of making a mold for a cast product having a plurality of airfoils disposed in a circular array, said method comprising the steps of providing a plurality of airfoil pattern segments formed of a relatively flexible and disposable material, providing a circular pattern member formed of a material having a greater rigidity than material forming the airfoil pattern segments, placing the airfoil pattern segments in a circular array engaging the circular pattern member to form a pattern assembly, said step of placing the airfoil pattern segments in a circular array includes placing the airfoil pattern segments in an array with joints between the airfoil pattern segments free of material interconnecting the airfoil pattern segments so that the airfoil pattern segments can be readily moved relative to each other, connecting the airfoil pattern segments with the circular pattern member to thereby retard movement of the airfoil pattern segments relative to each other and the circular pattern member while maintaining the joints between the airfoil pattern segments free of material interconnecting the airfoil pattern segments, repetitively dipping the pattern assembly in liquid ceramic mold material to form a covering of ceramic mold material overlying at least a portion of the pattern assembly, said step of dipping the pattern assembly in liquid ceramic mold material including the step of flowing liquid ceramic mold material into at least some of the joints between the airfoil pattern segments, at least partially supporting the airfoil pattern segments with the relatively rigid circular pattern member during said dipping steps, at least partially drying the covering of ceramic mold material overlying the pattern assembly, disposing of the airfoil pattern segments to expose a circular array of ceramic airfoil mold surfaces having configurations corresponding to the configurations of the airfoil pattern segments, moving the relatively rigid circular pattern member away from the ceramic airfoil mold surfaces after performing said step of disposing of the airfoil pattern segments, and removing projections of ceramic mold material at locations where the liquid ceramic mold material entered the joints between the airfoil pattern segments.

Claim 59

A method of making a mold for a cast product having a plurality of airfoils disposed in a circular array, said method comprising the steps of providing a plurality of airfoil pattern segments formed of a relatively flexible and disposable material, providing a circular pattern member formed of a material having a greater rigidity than material forming the airfoil pattern segments, placing the airfoil pattern segments in a circular array with radially outer end portions of the airfoil pattern segments engaging the circular pattern member to form a pattern assembly, clamping the radially outer end portion of each of the airfoil pattern segments to the circular pattern member, said step of placing the airfoil pattern segments in a circular array includes the step of placing the airfoil pattern segments in an array with joints between the airfoil pattern segments free of material interconnecting the airfoil pattern segments so that the airfoil pattern segments can be readily moved relative to each other prior to performance of said step of clamping radially outer end portions of the airfoil pattern segments to the circular pattern member, repetitively dipping the pattern assembly in liquid ceramic mold material to form a covering of ceramic mold material overlying at least a portion of the pattern assembly, said step of dipping the pattern assembly includes the step of flowing liquid ceramic mold material into at least some of the joints between the airfoil pattern segments, retarding relative movement between the airfoil pattern segments during said dipping steps by at least partially supporting the airfoil pattern segments with the relatively rigid circular pattern member, at least partially drying the covering of ceramic mold material overlying the pattern assembly, disposing of the airfoil pattern segments to expose a circular array of ceramic airfoil mold surfaces having configurations corresponding to the configurations of the airfoil pattern segments, moving the relatively rigid circular pattern member away from the ceramic airfoil mold surfaces, and removing projections of ceramic mold material at locations where the liquid ceramic mold material entered the joints between the airfoil pattern segments.

Claim 60

A method of making a mold for a cast product having a plurality of airfoils disposed in a circular array, said method comprising the steps of providing a plurality of airfoil pattern segments formed of a relatively flexible and disposable material, providing a circular pattern member formed of a material having a greater rigidity than material forming the airfoil pattern segments, placing the airfoil pattern segments in a circular array with radially outer end portions of the airfoil pattern segments engaging the circular pattern member to form a pattern assembly, clamping the radially outer end portion of each of the airfoil pattern segments to the circular pattern member, said step of placing the airfoil pattern segments in a circular array includes the step of placing the airfoil pattern segments in an array with joints between the airfoil pattern segments free of material interconnecting the airfoil pattern segments so that the airfoil pattern segments can be readily moved relative to each other prior to performance of said step of clamping radially outer end portions of the airfoil pattern segments to the circular pattern member, repetitively dipping the pattern assembly in liquid ceramic mold material to form a covering of ceramic mold material overlying at least a portion of the pattern assembly, said step of dipping the pattern assembly includes the step of flowing liquid ceramic mold material into at least some of the joints between the airfoil pattern segments, retarding relative movement between the airfoil pattern segments during said dipping steps by at least partially supporting the airfoil pattern segments with the relatively rigid circular pattern member, at least partially drying the covering of ceramic mold material overlying the pattern assembly, disposing of the airfoil pattern segments to expose a circular array of ceramic airfoil mold surfaces having configurations corresponding to the configurations of the airfoil pattern segments, moving the relatively rigid circular pattern member away from the ceramic airfoil mold surfaces, and removing projections of ceramic mold material at locations where the liquid ceramic mold material entered the joints between the airfoil pattern segments.

Claim 63

A method of making a mold for a casting product having a plurality of airfoils disposed in a circular array, said method comprising the steps of providing a plurality of wax airfoil pattern segments, providing a circular metal pattern member, clamping each of the wax airfoil pattern segments to the circular metal pattern member to form a circular array of airfoil pattern segments which are connected with the circular metal pattern member, leaving joints between the wax airfoil pattern segments free of material interconnecting the airfoil pattern segments, applying a covering of liquid ceramic mold material over exposed surface areas of the wax airfoil pattern segments and over at least a portion of the circular metal pattern member while the wax airfoil pattern segments are clamped to the circular metal pattern member, at least partially supporting the wax airfoil pattern segments with the circular metal pattern member during the application of the covering of liquid ceramic mold material to the airfoil pattern segments and to the pattern member, forming a circular discontinuity in the covering of ceramic mold material in an area overlying the circular pattern member while the covering of ceramic mold material is wet to at least partially divide the covering of ceramic mold material into portions which can be separated after performing said step of drying the covering of ceramic mold material, at least partially drying the covering of ceramic mold material overlying the wax airfoil pattern segments and circular metal pattern member, and disposing of the wax airfoil pattern segments while maintaining the circular metal pattern member intact and removing the circular pattern member to expose a circular array of ceramic airfoil mold surfaces having configurations corresponding to the configurations of the wax airfoil pattern segments.

Claim 64

A method of making a mold for a casting product having a plurality of airfoils disposed in a circular array, said method comprising the steps of providing a plurality of wax airfoil pattern segments, providing a circular metal pattern member, clamping each of the wax airfoil pattern segments to the circular metal pattern member to form a circular array of airfoil pattern segments which are connected with the circular metal pattern member, leaving joints between the wax airfoil pattern segments free of material interconnecting the airfoil pattern segments, applying a covering of liquid ceramic mold material over exposed surface areas of the wax airfoil pattern segments and over at least a portion of the circular metal pattern member while the wax airfoil pattern segments are clamped to the circular metal pattern member, at least partially supporting the wax airfoil pattern segments with the circular metal pattern member during the application of the covering of liquid ceramic mold material to the airfoil pattern segments and to the pattern member, forming a circular discontinuity in the covering of ceramic mold material in an area overlying the circular pattern member while the covering of ceramic mold material is wet to at least partially divide the covering of ceramic mold material into portions which can be separated after performing said step of drying the covering of ceramic mold material, at least partially drying the covering of ceramic mold material overlying the wax airfoil pattern segments and circular metal pattern member, and disposing of the wax airfoil pattern segments while maintaining the circular metal pattern member intact and removing the circular pattern member to expose a circular array of ceramic airfoil mold surfaces having configurations corresponding to the configurations of the wax airfoil pattern segments.