Method of manufacturing of a metallurgical mold

Claim 1

A method of making a mold for the directional solidification of a metall alloy composite to produce parts of complex shape of refractory directionally solidified polyvariant fiber-reinforced composite having eutectic-type structure consisting essentially of two distinct independent phases constituted by: (a) a complex multicomponent matrix phase consisting essentially of: i. at least one metal selected from the group consisting of Fe, Ni and Co, and ii. chromium in an amount between 10 and 25 percent by weight of the composite; and in said matrix: (b) an in situ grown reinforcing phase free from chromium and consisting essentially of whisker-like elongated monocrystalline fibers of at least one metal monocarbide, the metal of which is selected from the group constituted by Ta, Nb, Hf and Ti, said method comprising the steps of: preparing a model of a part to be produced by forming a wax shape of the part to be produced, chemically applying a silver film to said wax shape, and electrolytically depositing a metal forming an external surface of said model on said silver film, said external surface having a melting point sufficiently high to resist deposit by plasma or flame spraying of a refractory metal oxide selected from the group which consists of aluminum oxide, zirconium oxide and magnesium oxide having a purity of at least 99.5%; depositing by plasma or flame spraying onto said model a one piece thin, dense and nonporous shell of said oxide; and separating said shell from said model by a physical or chemical treatment whereby said separated shell forms said mold.

Claim 2

A method of making a mold for the directional solidification of a metall alloy composite to produce parts of complex shape of refractory directionally solidified polyvariant fiber-reinforced composite having eutectic-type structure consisting essentially of two distinct independent phases constituted by: (a) a complex multicomponent matrix phase consisting essentially of: i. at least one metal selected from the group consisting of Fe, Ni and Co, and ii. chromium in an amount between 10 and 25 percent by weight of the composite; and in said matrix: (b) an in situ grown reinforcing phase free from chromium and consisting essentially of whisker-like elongated monocrystalline fibers of at least one metal monocarbide, the metal of which is selected from the group constituted by Ta, Nb, Hf and Ti, said method comprising the steps of: preparing a model of a part to be produced by forming a wax shape of the part to be produced, chemically applying a silver film to said wax shape, and electrolytically depositing a metal forming an external surface of said model on said silver film, said external surface having a melting point sufficiently high to resist deposit by plasma or flame spraying of a refractory metal oxide selected from the group which consists of aluminum oxide, zirconium oxide and magnesium oxide having a purity of at least 99.5%; depositing by plasma or flame spraying onto said model a one piece thin, dense and nonporous shell of said oxide; and separating said shell from said model by a physical or chemical treatment whereby said separated shell forms said mold.