Systems, devices, and/or methods for producing holes
View Patent ↗Certain exemplary embodiments can provide a system, machine, device, manufacture, circuit, and/or composition of matter adapted for and/or resulting from, and/or a method for activities that can comprise and/or relate to, a first form comprising: a plurality of surface artifacts that substantially spatially replicate a surface geometry of a stacked foil mold; and a prong that is adapted to form a hole in a cast product.
1. A device comprising:
a metallic cast product comprising:
a first plurality of surface artifacts that are integral to the metallic cast product and substantially spatially replicate a surface geometry of a stacked foil mold from which the metallic cast product descended, wherein:
the first plurality of surface artifacts resemble seams but do not extend substantially below a surface of the metallic cast product; and
each surface artifact from the first plurality of surface artifacts geometrically replicates a thickness of a foil of the stacked foil mold; and
a product surface that defines a first hole, the first hole defining a hole longitudinal axis, an intersection of the product surface and a wall of the first hole defining a depth of the first hole, the intersection defining a fillet that is integral to the product, the fillet defining a first midpoint fillet depth measured in a first plane that contains the hole longitudinal axis, the fillet defining a second midpoint fillet depth measured in a second plane that contains the hole longitudinal axis, the first plane separated from the second plane by a predetermined angle measured perpendicular to the hole longitudinal axis, the fillet comprising one or more surface artifacts from the first plurality of surface artifacts.
2. The device of claim 1 , wherein:
the first midpoint fillet depth is measured at a longitudinal midpoint located approximately halfway between a first hole transition that is located where the fillet substantially blends into the first hole in the first plane and a product surface transition that is located where the fillet substantially blends into the product surface in the first plane.
3. The device of claim 1 , wherein:
the second midpoint fillet depth is measured at a longitudinal midpoint located approximately halfway between a second hole transition that is located where the fillet substantially blends into the first hole in the second plane and a product surface transition that is located where the fillet substantially blends into the product surface in the second plane.
4. The device of claim 1 , wherein:
the metallic cast product is comprised by at least a portion of an airfoil.
5. The device of claim 1 , wherein:
the metallic cast product substantially surrounds a form.
6. The device of claim 1 , wherein:
the metallic cast product is substantially surrounded by a form.
7. The device of claim 1 , wherein:
the first hole extends toward a second hole of the metallic cast product.
8. The device of claim 1 , wherein:
the first hole is a cooling hole for the metallic cast product.
9. The device of claim 1 , wherein:
the first hole is a through hole.
10. The device of claim 1 , wherein:
the first hole is a blind hole.
11. The device of claim 1 , wherein:
the first hole is structurally configured to be finished via a machining technique.
12. The device of claim 1 , wherein:
the first hole is structurally configured to extend from a wax pattern toward a predetermined target feature in a core or shell.
13. The device of claim 1 , wherein:
the first hole is one of an array of holes defined by and integral to the metallic cast product.
14. The device of claim 1 , wherein:
the product surface defines an extent of a predetermined coating.
15. The device of claim 1 , wherein:
the first hole comprises a first hole entry and/or exit that has a predetermined curvature.
16. The device of claim 1 , wherein:
the first hole defines a first hole cross-section that, at a predetermined depth of the first hole, is round.
17. The device of claim 1 , wherein:
the first hole defines a first hole cross-section that, at a predetermined depth of the first hole, is not round.
18. The device of claim 1 , wherein:
the first hole defines:
a first hole periphery that has a first predetermined shape as measured in a first predetermined longitudinal cross-sectional plane of the first hole that intersects a first predetermined position along the hole longitudinal axis; and
a second hole periphery that has a second predetermined shape as measured in a second predetermined longitudinal cross-sectional plane of the first hole that intersects a second predetermined position along the hole longitudinal axis, the first predetermined shape differing from the second predetermined shape.
19. The device of claim 1 , wherein:
the first hole defines:
a first hole cross-sectional area that is measured in a first predetermined longitudinal cross-sectional plane of the first hole that intersects a first predetermined position along the hole longitudinal axis; and
a second hole cross-sectional area that is measured in a second predetermined longitudinal cross-sectional plane of the first hole that intersects a second predetermined position along the hole longitudinal axis
the first hole cross-sectional area differing from the second hole cross-sectional area.
20. The device of claim 1 , wherein:
the hole longitudinal axis is not perpendicular to a longitudinal axis of the metallic cast product.
21. The device of claim 1 , wherein:
the hole longitudinal axis is curved with respect to a longitudinal axis of the metallic cast product.
22. The device of claim 1 , wherein:
the device defines a counter-sunk and/or moat-like region adjacent an entrance and/or exit of the first hole.
23. The device of claim 1 , wherein:
the product surface defines a fiducial on a sidewall of the first hole and/or a bottom of the first hole, the fiducial structurally configured to locate a second hole and/or align a traditional machining technique with the first hole.
24. The device of claim 1 , wherein:
the product surface defines a channel connecting the first hole to a second hole, that channel potentially extending between the first hole and the second hole at any position along a length of the first hole.
25. The device of claim 1 , wherein:
the metallic cast product surface defines a stress, fatigue, and/or crack reduction feature.
26. The device of claim 1 , wherein:
the product surface has a predetermined surface geometry.
27. The device of claim 1 , wherein:
the product surface has a predetermined surface roughness.
28. The device of claim 1 , wherein:
the product surface is dimpled.
29. The device of claim 1 , wherein:
the metallic cast product defines filtering projections within the first hole.
30. The device of claim 1 , wherein:
the metallic cast product defines a filtering feature within the first hole.
31. The device of claim 1 , wherein:
the metallic cast product defines blind pockets within the first hole.
32. The device of claim 1 , wherein:
the metallic cast product has a plurality of inner cavities.
33. The device of claim 1 , wherein:
the metallic cast product has a plurality inner cavities that are interconnected via one or more passages.
34. The device of claim 1 , wherein:
the first plurality of surface artifacts substantially invertedly spatially replicate the surface geometry of the first stacked foil mold.
35. The device of claim 1 , wherein:
the first plurality of surface artifacts comprise at least one protruding undercut.
36. The device of claim 1 , wherein:
wherein at least a portion of the plurality of surface artifacts resemble substantially linear seams.
37. The device of claim 1 , wherein:
wherein at least a portion of the plurality of surface artifacts resemble substantially non-linear seams.
38. A method comprising:
casting a metallic cast product comprising:
a first plurality of surface artifacts that are integral to the metallic cast product, wherein:
the first plurality of surface artifacts resemble seams but do not extend substantially below a surface of the metallic cast product; and
each surface artifact from the first plurality of surface artifacts geometrically replicates a thickness of a foil of a stacked foil mold; and
a product surface that defines a first hole, the first hole defining a hole longitudinal axis, an intersection of the product surface and a wall of the first hole defining a depth of the first hole, the intersection defining a fillet that is integral to the product, the fillet defining a first midpoint fillet depth measured in a first plane that contains the hole longitudinal axis, the fillet defining a second midpoint fillet depth measured in a second plane that contains the hole longitudinal axis, the first plane separated from the second plane by a predetermined angle measured perpendicular to the hole longitudinal axis, the fillet comprising one or more surface artifacts from the first plurality of surface artifacts.