1. A method of casting a component, the method comprising:
forming a plurality of sheets of fugitive material, each sheet corresponding to a respective layer of a desired three dimensional structure, at least some of the sheets each containing a respective void area in a location corresponding to a location of a first passageway within the desired three dimensional structure;
stacking the sheets to form the three dimensional structure, void areas in predetermined adjacent sheets being aligned to define the first passageway within the three dimensional structure, wherein the three dimensional structure comprises an outer perimeter defining a fugitive mold die;
injecting ceramic material slurry into the three dimensional structure and allowing the ceramic material to harden, the first passageway thus being filled with the ceramic material in a shape corresponding to the first passageway, wherein the fugitive mold die is filled with the ceramic material while forming an outer ceramic shell at the outer perimeter of the three dimensional structure, the forming of the outer ceramic shell in the fugitive mold die effective to eliminate a lost wax process in connection with the forming of the outer ceramic shell;
removing the fugitive material from the hardened ceramic material to reveal a cast ceramic component;
prior to removing the fugitive material, providing an external shell structure that substantially surrounds the three dimensional structure, the external shell structure and the cast ceramic component together forming a casting vessel for receiving molten alloy material after removal of the fugitive material;
injecting the molten alloy material into the cast ceramic component and allowing the alloy material to harden, the shape of the first passageway thereby being reproduced in the alloy material; and
removing the cast ceramic component from the hardened alloy material to reveal a cast alloy component having an interior passageway.
2. The method of claim 1, further comprising:
surrounding the three dimensional structure with the external shell structure.
3. The method of claim 1, further comprising:
incorporating the external shell structure into the layers of the three dimensional structure.
4. The method of claim 1, further comprising:
forming a first portion of the plurality of sheets of fugitive material to have a first thickness for a first region of the three dimensional structure; and forming a second portion of the plurality of sheets of fugitive material to have a second thickness different than the first thickness for a second region of the three dimensional structure.
5. The method of claim 1, further comprising
casting the sheets of fugitive material in at least two different master molds.
6. The method of claim 1, further comprising
forming the sheets of fugitive material by cutting respective voids into respective integral sheets of the fugitive material.
7. The method of claim 1, wherein:
a respective thickness of individual sheets of the plurality of sheets is selectively varied over respective regions of the three dimensional structure based on profile variation of the first passageway over the respective regions of the three dimensional structure.
8. The method of claim 1, wherein:
the first passageway is convoluted.
9. The method of claim 1, wherein:
the first passageway weaves left, right, up, and down within the three dimensional structure.
10. The method of claim 1, wherein:
a portion of the plurality of sheets defines a second passageway within the desired three dimensional structure.
11. The method of claim 1, wherein:
a portion of the plurality of sheets defines a second passageway that weaves left, right, up, and down within the three dimensional structure.
12. The method of claim 1, wherein:
a portion of the plurality of sheets defines a second passageway within the desired three dimensional structure, the second passageway interconnected with the first passageway.
13. The method of claim 1, wherein:
a portion of the plurality of sheets defines a second passageway within the desired three dimensional structure, the second passageway not interconnected with the first passageway, the second passageway configured to be filled with a ceramic material.
14. The method of claim I, wherein:
the plurality of sheets are stacked in an alternating arrangement.
15. The method of claim 1, wherein:
the plurality of sheets are stacked in an alternating arrangement that is configured so that shapes of adjoining void areas define at least one three dimensional convoluted passage through the three dimensional structure.
16. The method of claim 1, wherein:
the plurality of sheets are stacked in an alternating arrangement that is configured so that shapes of adjoining void areas define the first passageway as a convoluted passage through the three dimensional structure.
17. The method of claim 1, wherein:
the plurality of sheets are stacked in an alternating arrangement that is configured so that shapes of adjoining void areas define a plurality of three dimensional convoluted passages through the three dimensional structure.
18. The method of claim 1, wherein:
the cast alloy component comprises a trailing edge portion of a gas turbine airfoil.
19. A method comprising:
forming a plurality of sheets of fugitive material, each sheet corresponding to a respective layer of a desired three dimensional structure, each sheet defining a respective plurality of void areas;
stacking the plurality of sheets to form the three dimensional structure, the plurality of void areas in predetermined adjacent sheets being aligned to define respective portions of a plurality of convoluted passageways within the three dimensional structure, wherein the three dimensional structure comprises an outer perimeter defining a fugitive mold die;
injecting ceramic material slurry into the three dimensional structure and allowing the ceramic material to harden, wherein the ceramic material slurry forms an outer ceramic shell at the outer perimeter of the three dimensional structure, the forming of the outer ceramic shell in the fugitive mold die effective to eliminate a lost wax process in connection with the forming of the outer ceramic shell;
removing the fugitive material from the hardened ceramic material to reveal a cast ceramic component;
prior to removing the fugitive material, providing an external shell structure that substantially surrounds the three dimensional structure, the external shell structure and the cast ceramic component together forming a casting vessel for receiving molten alloy material after removal of the fugitive material;
injecting the molten alloy material into the cast ceramic component and allowing the alloy material to harden, the shape of the plurality of convoluted passageways thereby being reproduced in the alloy material; and
removing the cast ceramic component from the hardened alloy material to reveal a cast alloy component having a plurality of convoluted interior passageways.
The claims below are in addition to those above.
All refrences to claim(s) which appear below refer to the numbering after this setence.
1. An electronic lock, the electronic lock comprising:
a locking mechanism comprising a bolt and extensions coupled with the bolt;
a cartridge comprising a body portion and extension receiving portions, the extension receiving portions configured to receive the extensions of the locking mechanism;
a first coil positioned around the cartridge;
a core disposed within the cartridge and substantially within the first coil;
a first sliding barrier disposed within the cartridge and comprising a first magnetic material, the first sliding barrier selectively in communication with one or more of the extensions of the locking mechanism, the first sliding barrier being located on a first side of the core and being magnetically attracted to the core;
a second sliding barrier disposed within the cartridge and comprising a second magnetic material, the second sliding barrier selectively in communication with one or more of the extensions of the locking mechanism, the second sliding barrier being located on a second side of the core and being magnetically attracted to the core;
a second coil positioned around the cartridge, the second coil being spaced from the first coil and being positioned on the first side of the core;
a third coil positioned around the cartridge, the third coil being spaced from the first coil and being positioned on the second side of the core; and
a control circuit in communication with the first, second, and third coils, the control circuit operative to:
energize the first coil to create a magnetic field in the core, the magnetic field causing the first and second sliding barriers to move away from the core, and
energize the second and third coils after a predetermined time has elapsed, such that the first sliding barrier is magnetically attracted to the second coil and the second sliding barrier is magnetically attracted to the third coil, thereby allowing actuation of the locking mechanism.
2. The electronic lock of claim 1, wherein the control circuit is further configured to de-energize the first coil in response to energizing the second and third coils.
3. The electronic lock of claim 1, wherein a first length of the second coil is substantially the same as a length of the first sliding barrier and wherein a second length of the third coil is substantially the same as a length of the second sliding barrier.
4. The electronic lock of claim 1, wherein the first and second magnetic materials comprise neodymium.
5. An electronic lock, the electronic lock comprising:
a locking mechanism comprising a bolt and one or more extensions coupled with the bolt;
a cartridge comprising a body portion and one or more extension receiving portions, the one or more extension receiving portions configured to receive the one or more extensions of the locking mechanism;
a first coil positioned around the cartridge;
a core disposed within the cartridge and substantially within the first coil;
a second coil positioned around the cartridge, the second coil being spaced from the first coil;
a first sliding barrier disposed within the cartridge, the first sliding barrier selectively in communication with the one or more extensions of the locking mechanism; and
a control circuit operative to energize the first and second coils to cause the first sliding barrier to move from a first position magnetically attracted to the core to a second position magnetically attracted to the second coil and thereby allow actuation of the locking mechanism.
6. The electronic lock of claim 5, wherein the control circuit is further operative to energize the second coil at a predetermined time after energizing the first coil.
7. The electronic lock of claim 5, wherein the control circuit is further operative to energize the second coil once at least half of the first sliding barrier has passed within the second coil.
8. The electronic lock of claim 5, wherein the control circuit is further operative to energize the second coil once at least 60% of the first sliding barrier has passed within the second coil.
9. The electronic lock of claim 5, wherein the first sliding barrier comprises a magnetic material.
10. The electronic lock of claim 9, wherein the magnetic material comprises neodymium.
11. The electronic lock of claim 5, wherein a length of the second coil is approximately the same as a length of the first sliding barrier.
12. The electronic lock of claim 5, further comprising a second sliding barrier located on an opposite side of the core as the first sliding barrier and a third coil positioned around the cartridge, the third coil being spaced from the first coil.
13. The electronic lock of claim 12, wherein the second sliding barrier is configured to move from a third position magnetically attracted to the core to a fourth position magnetically attracted to the third coil in response to the control circuit energizing the first and third coils.
14. The electronic lock of claim 5 in combination with a key, the key comprising one or more shear pins configured to mate with one or more corresponding receptacles in the lock.
15. A method of actuating an electronic lock, the method comprising:
energizing a first coil positioned around a cartridge of a lock assembly to generate a first magnetic field within the cartridge;
using the first magnetic field to repel a barrier slidably disposed within the cartridge and in communication with a locking mechanism, said repelling causing the barrier to move from the first coil toward a second coil positioned around the cartridge;
energizing the second coil to generate a second magnetic field in the coil; and
using the second magnetic field to attract the barrier to the second coil, such that the barrier moves away from the locking mechanism and thereby allows movement of the locking mechanism.
16. The method of claim 15, wherein said energizing the second coil comprises energizing the second coil at a predetermined time after energizing the first coil.
17. The method of claim 15, wherein said energizing the second coil comprises energizing the second coil in response to at least half of the first sliding barrier passing through the second coil.
18. The method of claim 15, further comprising de-energizing the first coil in response to said energizing the second coil.
19. The method of claim 15, further comprising de-energizing the second coil after a predetermined period of time.
20. The method of claim 15, wherein the barrier comprises a bar magnet.