초록 ▼

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 s

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.

대표청구항 ▼

1. A device comprising: a ceramic or wax first form comprising: a first plurality of surface artifacts that are integral to the first form and that substantially spatially replicates a surface geometry of a first stacked foil mold from which the first form descended, wherein: the first plurality of

1. A device comprising: a ceramic or wax first form comprising: a first plurality of surface artifacts that are integral to the first form and that substantially spatially replicates a surface geometry of a first stacked foil mold from which the first form descended, wherein: the first plurality of surface artifacts resemble seams but do not extend substantially below a surface of the first form; andeach surface artifact from the first plurality of surface artifacts geometrically replicates a thickness of a foil of the first stacked foil mold; anda first prong that: has a predominantly ceramic composition;is integral to the first form;is structurally configured to form a first hole in a metallic cast product that is cast in a molten state substantially around the first prong;is structurally configured to substantially structurally disintegrate due to thermal stresses imparted on the first prong as the metallic cast product cools from a molten state to a solid state; anddefines a prong longitudinal axis, an intersection of the first form and the first prong defining a fillet that is integral to the first prong and the first form, the fillet defining a first midpoint fillet depth measured in a first plane that contains the prong longitudinal axis, the fillet defining a second midpoint fillet depth measured in a second plane that contains the prong longitudinal axis, the first plane separated from the second plane by a predetermined angle measured perpendicular to the prong 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 prong transition that is located where the fillet substantially blends into the first prong in the first plane and a first form transition that is located where the fillet substantially blends into the first form 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 prong transition that is located where the fillet substantially blends into the first prong in the second plane and a second form transition that is located where the fillet substantially blends into the first form in the second plane. 4. The device of claim 1, wherein: an external surface of the fillet is defined by an external surface of the first form and an exterior surface of the first prong. 5. The device of claim 1, wherein: the cast product is comprised by at least a portion of an airfoil. 6. The device of claim 1, wherein: the first form defines at least a portion of a ceramic core. 7. The device of claim 1, wherein: the first form defines at least a portion of a wax mold. 8. The device of claim 1, wherein: at least a portion of the first form is structurally configured to be replaced by a molten metallic alloy that, upon solidification, creates at least a portion of the cast product. 9. The device of claim 1, wherein: the cast product is structurally configured to be cast substantially around the first form. 10. The device of claim 1, wherein: the cast product is structurally configured to be cast substantially within the form. 11. The device of claim 1, wherein: the first prong is structurally configured to be destructively removed from the cast product. 12. The device of claim 1, wherein: the first prong extends outwardly with respect to a predetermined axis of the first form. 13. The device of claim 1, wherein: the first prong extends inwardly with respect to a predetermined axis of the first form. 14. The device of claim 1, wherein: the first prong extends outwardly with respect to a predetermined axis of the first form and toward a second prong that extends inwardly from a shell or mold. 15. The device of claim 1, wherein: the first prong extends inwardly with respect to a predetermined axis of the first form toward a second prong that extends outwardly with respect to a predetermined axis of a core. 16. The device of claim 1, wherein: the first prong is structurally configured to form a cooling hole in the metallic cast product. 17. The device of claim 1, wherein: the first prong is structurally configured to form a through hole in the metallic cast product. 18. The device of claim 1, wherein: the first prong is structurally configured to form a blind hole in the metallic cast product. 19. The device of claim 1, wherein: the first hole is structurally configured to be finished via a machining technique. 20. The device of claim 1, wherein: the first prong is structurally configured to extend from the first form toward a predetermined target feature in a wax pattern or shell. 21. 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. 22. The device of claim 1, wherein: the first prong is one of an array of prongs defined by and integral to the first form. 23. The device of claim 1, wherein: the first prong is coated with a predetermined material. 24. The device of claim 1, wherein: the first prong is a composite, reinforced structure. 25. The device of claim 1, wherein: the first prong is consumable. 26. The device of claim 1, wherein: the first prong defines a first hole entry and/or exit that has a predetermined curvature. 27. The device of claim 1, wherein: the first prong defines a first hole cross-section that, at a predetermined depth of the first hole, is round. 28. The device of claim 1, wherein: the first prong defines a first hole cross-section that, at a predetermined depth of the first hole, is not round. 29. The device of claim 1, wherein: the first prong defines: a first prong periphery that has a first predetermined shape as measured in a first predetermined longitudinal cross-sectional plane of the first prong that intersects a first predetermined position along the prong longitudinal axis; anda second prong periphery that has a second predetermined shape as measured in a second predetermined longitudinal cross-sectional plane of the first prong that intersects a second predetermined position along the prong longitudinal axis, the first predetermined shape differing from the second predetermined shape. 30. The device of claim 1, wherein: the first prong defines: a first prong cross-sectional area that is measured in a first predetermined longitudinal cross-sectional plane of the first prong that intersects a first predetermined position along the prong longitudinal axis; anda second prong cross-sectional area that is measured in a second predetermined longitudinal cross-sectional plane of the first prong that intersects a second predetermined position along the prong longitudinal axisthe first prong cross-sectional area differing from the second prong cross-sectional area. 31. The device of claim 1, wherein: the prong longitudinal axis is not perpendicular to a longitudinal axis of the first form. 32. The device of claim 1, wherein: the prong longitudinal axis is curved with respect to a longitudinal axis of the first form. 33. 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. 34. The device of claim 1, wherein: the first prong 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. 35. The device of claim 1, wherein: the first prong 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. 36. The device of claim 1, wherein: an outer surface of the first prong defines a stress, fatigue, and/or crack reduction feature. 37. The device of claim 1, wherein: an outer surface of the first prong defines a predetermined surface geometry. 38. The device of claim 1, wherein: an outer surface of the first prong defines a predetermined surface roughness. 39. The device of claim 1, wherein: an outer surface of the first prong is dimpled. 40. The device of claim 1, wherein: the first prong defines filtering projections. 41. The device of claim 1, wherein: the first prong defines a filtering feature. 42. The device of claim 1, wherein: the first prong defines blind pockets. 43. The device of claim 1, wherein: the first form comprises a rubber liner attached to a metal base, the liner structurally configured to define a shape of the first form, the liner comprising a second plurality of surface artifacts that are integral to the liner and that substantially spatially mirror a surface of a second stacked foil mold from which the liner descended, wherein: the second plurality of surface artifacts resemble seams but do not extend substantially below a surface of the liner; andeach surface artifact from the second plurality of surface artifacts geometrically replicates a thickness of a foil of the second stacked foil mold. 44. The device of claim 1, wherein: the device defines a plurality of inner cavities in the cast product. 45. The device of claim 1, wherein: the device defines a pair of cast product inner cavities that are interconnected via one or more passages. 46. 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. 47. The device of claim 1, wherein: the first plurality of surface artifacts comprise at least one protruding undercut. 48. The device of claim 1, wherein: the ceramic composition is structurally configured to undergo a crystal structure change, from one polymorph of a solid material to another polymorph, prior to the metallic cast product being cast around the first prong. 49. The device of claim 1, wherein: wherein at least a portion of the plurality of surface artifacts resemble substantially linear seams. 50. The device of claim 1, wherein: wherein at least a portion of the plurality of surface artifacts resemble substantially non-linear seams. 51. A method comprising: within a first portion of a ceramic or wax investment casting mold and a second portion of the casting mold, at least one of the first portion and the second portion being a first form comprising: a first plurality of surface artifacts that are integral to the first form and that substantially spatially replicate a surface geometry of a first stacked foil mold from which the first form descended, wherein: the first plurality of surface artifacts resemble seams but do not extend substantially below a surface of the first form; andeach surface artifact from the first plurality of surface artifacts geometrically replicates a thickness of a foil of the first stacked foil mold; anda first prong that: has a predominantly ceramic composition;is integral to the first form;is structurally configured to form a first hole in a metallic cast product that is cast in a molten state substantially around the first prong;is structurally configured to substantially structurally disintegrate due to thermal stresses imparted on the first prong as the metallic cast product cools from a molten state to a solid state; anddefines a prong longitudinal axis, an intersection of the first form and the first prong defining a fillet that is integral to the first prong and the first form, the fillet defining a first midpoint fillet depth measured in a first plane that contains the prong longitudinal axis, the fillet defining a second midpoint fillet depth measured in a second plane that contains the prong longitudinal axis, the first plane separated from the second plane by a predetermined angle measured perpendicular to the prong longitudinal axis, the fillet comprising one or more surface artifacts from the first plurality of surface artifacts, casting the cast product.