Edward John Day

43388787, Jul 13, 1982

Nov 26, 1980

6/210482

Kenneth R. Mason - Wethersfield CT
Edward G. Day - Rocky Hill CT

United Technologies Corporation - Hartford CT

B05C 1902

118429

A fluidized bed has an aperture plate which is inclined to the horizontal, to cause excessively large or dense particles to migrate to a collection point from which they may be removed from the particulate mass. Disruption of fluid flow through the aperture plate due to settled out particles is thus avoided. Preferably the aperture plate is made of a material which has the same permeability as the fluidized mass, thus inherently providing flow regulation necessary for even fluidization above the slope plate. To make investment casting molds, a gravity "rainsander" device is coupled with a fluidized bed. When slurry used in the mold making process drips from a pattern it falls into the fluidized bed thereby converting the errant drops into particulate balls which are conveniently removed.

40623963, Dec 13, 1977

Jan 5, 1976

5/646804

Edward George Day - Rocky Hill CT

United Technologies Corporation - Hartford CT

B22C 700

164 15

This invention involves a method of making a unitary pattern assembly which is useful in forming investment shell molds for the conventional and directional solidification of molten metals and alloys. It comprises providing a fixture having first and second pattern capturing means, providing a mold structure having a cavity, positioning the mold structure and fixture to expose the capturing means to the cavity, forming a pattern in the cavity and removing the mold structure from the pattern. A unitary pattern assembly comprising a fixture and pattern fixedly captured therein is obtained. Multiple patterns may also be captured in the fixture. The method is especially suitable for making a pattern assembly useful in the production of gas turbine engine blades by the "lost wax" process.

39304620, Jan 6, 1976

May 8, 1975

5/575754

Edward G. Day - Rocky Hill CT

United Technologies Corporation - Hartford CT

B05C 304

118 5

An enclosure designed to maintain the purity and physical characteristics of a slurry within a preferred range during the manufacture of shell molds is disclosed. The tank is in the form of a trough with flat side walls and a curved member forming the front, bottom and back of the trough. The entire trough is water cooled and a cover along the top completes the enclosure. The enclosure is fitted with means for circulating the slurry and a liner having an airfoil member. Various sensing and control means are interconnected through a feedback system which continuously monitors and controls the conditions of the slurry.

40572277, Nov 8, 1977

Aug 27, 1976

5/718265

Carlton E. Cruff - Manchester CT
Edward G. Day - Rocky Hill CT

United Technologies Corporation - Hartford CT

B28C 546

366 2

The present invention provides an improved method for making ceramic slurries useful in forming casting molds. The method involves placing the slurry ingredients in a mixing container, removing sufficient air from the container to prevent subsequent air entrapment, mixing the slurry ingredients by epicyclic agitation to effect rapid particle wetting and homogenization and removing the slurry from the container after agitation is terminated, the ceramic slurry being ready for immediate use. Total slurry preparation time is generally one hour or less, as compared to the 24 to 36 or more hours required for prior art slurry preparation techniques.

41112520, Sep 5, 1978

Aug 1, 1977

5/820659

Edward G. Day - Rocky Hill CT
Edmund Dziobek - Terryville CT

United Technologies Corporation - Hartford CT

B22C 904
B22C 700
B22D 1502

164 23

Disclosed is an improved method for making molds and mold components for use in casting single crystal articles. According to the improved method, a preformed and reusable replica of a mold growth cavity and crystal selector passage is provided, the replica including a cylinder in the form of the desired growth cavity and a helical strand in the form of the desired crystal selector passage, one end of the strand being attached to an end of the cylinder such that their axes are coincident. In one embodiment, the replica is coated with a thin layer of wax or other removable material and then utilized in a variety of mold making processes, including investment molding, to form a growth zone and helical crystal selector in the mold. After mold making, the embedded replica is removed from the mold by first removing the thin layer of wax to provide a clearance space between the replica and mold and then rotating the cylinder to unscrew the helical strand from the mold in the same manner that a threaded member is removed from a threaded hole. The replica is then reused to produce additional molds or mold components having a reproducible growth zone and helical crystal selector therein.