US 11,654,476 B2
Hybrid core for manufacturing of castings
Lokesh Choudhary, Karnataka (IN); Tiruttani Munikamal, Karnataka (IN); Qigui Wang, Rochester Hills, MI (US); and Liang Wang, Rochester Hills, MI (US)
Assigned to GM Global Technology Operations LLC, Detroit, MI (US)
Filed by GM GLOBAL TECHNOLOGY OPERATIONS LLC, Detroit, MI (US)
Filed on Sep. 28, 2020, as Appl. No. 17/34,530.
Prior Publication US 2022/0097125 A1, Mar. 31, 2022
Int. Cl. B22C 9/10 (2006.01); B22D 15/00 (2006.01); B22D 17/22 (2006.01)
CPC B22C 9/103 (2013.01) [B22D 15/00 (2013.01); B22D 17/22 (2013.01)] 20 Claims
OG exemplary drawing
 
1. A hybrid core for manufacturing a cast component, the hybrid core comprising:
a sand core portion having an exterior shape arranged along a longitudinal axis and configured to define an interior feature of the cast component; and
a metal chill element fully embedded within the sand core portion and covered thereby in a cross-sectional view orthogonal to the longitudinal axis and configured to locally absorb heat energy from the cast component during cooling of the cast component and solidification thereof, and constructed and arranged within the sand core portion to be removed during shake out from the cast component subsequent to the solidification thereof.
 
11. A system for manufacturing a cast component, the system comprising:
a mold having a first half and a second half defining an inner cavity configured to form an exterior shape of the cast component;
a hybrid core arranged within the inner cavity of the mold and configured to define an interior feature of the cast component, the hybrid core including:
a sand core portion having an exterior shape arranged along a longitudinal axis and configured to define the interior feature of the cast component; and
a metal chill element fully embedded within the sand core portion and covered thereby in a cross-sectional view orthogonal to the longitudinal axis and configured to locally absorb heat energy from the cast component during cooling of the cast component and solidification thereof, and constructed and arranged within the sand core portion to be removed during shake out from the cast component subsequent to the solidification thereof; and
a mechanism for introducing a molten material into the cavity to form the cast component such that the molten material flows into the cavity and around the hybrid core to form the exterior shape and the interior feature of the cast component.