CN104624962A - Laser assisted casting and related system - Google Patents

Laser assisted casting and related system Download PDF

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Publication number
CN104624962A
CN104624962A CN201410641865.6A CN201410641865A CN104624962A CN 104624962 A CN104624962 A CN 104624962A CN 201410641865 A CN201410641865 A CN 201410641865A CN 104624962 A CN104624962 A CN 104624962A
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China
Prior art keywords
laser
wax
transformation
additional features
laser ablation
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CN201410641865.6A
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Chinese (zh)
Inventor
胡兆力
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General Electric Co
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General Electric Co
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Publication of CN104624962A publication Critical patent/CN104624962A/en
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22CFOUNDRY MOULDING
    • B22C9/00Moulds or cores; Moulding processes
    • B22C9/02Sand moulds or like moulds for shaped castings
    • B22C9/04Use of lost patterns
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22CFOUNDRY MOULDING
    • B22C7/00Patterns; Manufacture thereof so far as not provided for in other classes
    • B22C7/02Lost patterns
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22CFOUNDRY MOULDING
    • B22C9/00Moulds or cores; Moulding processes

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Laser Beam Processing (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
  • Application Of Or Painting With Fluid Materials (AREA)

Abstract

Various embodiments include methods and related systems for laser-assisted casting. Some embodiments include a method including: performing laser ablation to a preliminary wax casting model to form a modified wax model including at least one additional feature absent from the wax casting substrate; coating the modified wax model to form a mold shape around the modified wax model; and removing the modified wax model to leave a casting mold including the at least one additional feature.

Description

Laser assisted casting and related system
Technical field
A kind of materials processing is the present invention relates to disclosed in this description.Specifically, the present invention relates to and cast shape in the material.
Background technology
Part is such as the mould of formation one shape for the conventional casting methods of the metal parts in the such as machine such as turbine and/or electrically powered machine, then by liquefied material (such as, metal) cast or otherwise deposit in described mould.Then described liquefied material is cooled, to form the cured portion in mould split shed shape.The traditional forming methods of mould is structure wax shape; Apply described wax shape, such as, apply one or more ceramic layer; And except dewax, and leave the profile of this shape, as the mould of casting liquefied material.
Given shape in part may be difficult to be formed and/or with high costs, because be not always easy to handle for the formation of the wax base material of these shapes.In some cases, first formation " substantially " (or, generally) wax base material, then adds other features by carrying out machining to this wax base material to this wax model, to be formed coated and form the feature of this part subsequently.This technique may be very expensive, consuming time and complicated.
Additive method adds the feature forming wax model before being included in and forming mould to wax molding tool.This may be faster than transforming after formation wax mold, but may be very expensive, because need to reshape whole wax molding tool.In addition, transform original wax molding tool and may cause feature such as, conflict between the feature that different directions extends.Can also use collecting of sub-wax model and wax model, but these methods will form seam, need correcting afterwards.
Summary of the invention
Multiple embodiment comprises the method and related system of casting for laser assisted.Some embodiments comprise a kind of method, and described method comprises: provide preliminary wax casting pattern; Perform laser ablation to form the wax model of transformation to described preliminary wax casting pattern, the wax model of described transformation comprises at least one additional features non-existent in described preliminary wax casting pattern; Apply the wax model of described transformation, to form the mold shape of the wax model around described transformation; And remove the wax model of described transformation, and leave the casting mould comprising at least one additional features described.
A first aspect of the present invention comprises a kind of method, described method comprises: perform laser ablation to form the wax model of transformation to preliminary wax casting pattern, the wax model of described transformation comprises at least one additional features non-existent in described preliminary wax casting pattern; Apply the wax model of described transformation, to form the mold shape of the wax model around described transformation; And remove the wax model of described transformation, and leave the casting mould comprising at least one additional features described.
A second aspect of the present invention comprises a kind of system, described system comprises: laser system, described laser system is through programming to perform to preliminary wax casting pattern the wax model that laser ablation forms transformation, and the wax model of described transformation comprises at least one additional features non-existent in described preliminary wax casting pattern; Imaging system, for scanning the wax model of described transformation after performing laser ablation, to form the image of at least one additional features described; Application system, for applying the wax model of described transformation, to form the mold shape of the wax model around described transformation, and removes the wax model of described transformation, and leaves the casting mould comprising at least one additional features described; And casting system, cast shape for using the casting mould with at least one additional features described by founding materials.
A third aspect of the present invention comprises a kind of method, described method comprises: perform laser ablation to form the wax model of transformation to preliminary wax casting pattern, the wax model of described transformation comprises at least one additional features non-existent in described preliminary wax casting pattern, the described laser ablation of wherein said execution comprises to described preliminary wax casting pattern applying pulse laser, directly to evaporate a part for described preliminary wax casting pattern, form at least one additional features described, wherein said direct evaporation comprises: the local temperature of the described part of described preliminary wax casting pattern is elevated to more than about 500 degrees Celsius, and the temperature of the adjacent part of described preliminary wax casting pattern is maintained lower than about 120 degrees Celsius, and after performing described laser ablation, scan the wax model of described transformation, to form the image of at least one additional features described.
Accompanying drawing explanation
These and other features of the present invention more easily can be understood to the detailed description of each side of the present invention below reading in conjunction with the accompanying drawing describing the multiple embodiment of the present invention, in the accompanying drawings:
Fig. 1 shows the schematic diagram of the system for laser assisted casting according to the multiple embodiment of the present invention.
Fig. 2 shows the flow chart of the technique according to the multiple embodiment of the present invention.
Fig. 3 shows the process flow diagram of signal according to the technique in formation casting shape of the multiple embodiment of the present invention.
It should be noted that accompanying drawing of the present invention is not necessarily drawn in proportion.Therefore accompanying drawing only for describing typical pattern of the present invention, and should not be considered as limiting the scope of the invention.In the accompanying drawings, element similar in similar numeral accompanying drawing.
Detailed description of the invention
As mentioned above, the present invention disclosed in this specification relates to materials processing.Specifically, the present invention relates to and cast shape in the material.
As described in this description, the given shape in part may be difficult to be formed and/or with high costs, because be not always easy to handle for the formation of the wax base material of these shapes.In some cases, first formation " substantially " (or, generally) wax base material, then adds other features by carrying out machining to this wax base material to this wax model, to be formed coated and with the feature of this part of postforming.This technique may be very expensive, consuming time and complicated.
Specifically, traditional turbine parts casting comprises structure wax molding tool, and it comprises the shape of the wax model that will pour into a mould.After constructing described wax molding tool, wax is poured in described instrument, to produce described wax model.Apply described wax model (such as, having in the coating slurry of nearly 20 to 30 layers) subsequently, to form the housing (mold shape) around described wax model.Comprise wax with back casing (mold shape) and heated to remove described wax model, retain described mold shape (as casting mould).Heated metal is poured in described mold shape (housing) afterwards, then cools the metallic member forming the shape having wax model.Remove described mold shape (housing) subsequently, such as, removed by machinery or chemical mode.The forward direction wax molding tool that some conventional methods are attempted forming described wax model adds feature.This may be faster than transforming after formation wax mold, but may be very expensive, because need to reshape whole wax molding tool.In addition, transform original wax molding tool and may cause feature such as, conflict between the feature that different directions extends.Can also use collecting of sub-wax model and wax model, but these methods will form seam, need correcting afterwards.
In order to solve the problem in traditional molding/casting method, many aspects of the present invention comprise for effectively transforming existing mold to comprise the solution of additional features.
Multiple particular aspects of the present invention comprises a kind of method, and described method comprises: provide preliminary wax casting pattern (optional preprocessing); Perform laser ablation to form the wax model of transformation to described preliminary wax casting pattern, the wax model of described transformation comprises at least one additional features non-existent in described preliminary wax casting pattern; Apply the wax model of described transformation, to form the mold shape of the wax model around described transformation; And remove the wax model of described transformation, and leave the casting mould comprising at least one additional features described.
Other particular aspects multiple of the present invention comprise a kind of system, described system comprises: laser system, described laser system is through programming to perform to preliminary wax casting pattern the wax model that laser ablation forms transformation, and the wax model of described transformation comprises at least one additional features non-existent in described preliminary wax casting pattern; Imaging system, for scanning the wax model of described transformation after performing laser ablation, to form the image of at least one additional features described; Application system, for applying the wax model of described transformation, to form the mold shape of the wax model around described transformation, and removes the wax model of described transformation, and leaves the casting mould comprising at least one additional features described; And casting system, cast shape for using the casting mould with at least one additional features described by founding materials.
Other aspects of the present invention comprise a kind of method, and described method comprises: provide preliminary wax casting pattern (optional preprocessing); Laser ablation is performed to form the wax model of transformation to described preliminary wax casting pattern, the wax model of described transformation comprises at least one additional features non-existent in described preliminary wax casting pattern, the described laser ablation of wherein said execution comprises to described preliminary wax casting pattern applying pulse laser, directly to evaporate a part for described preliminary wax casting pattern, form at least one additional features described, wherein said direct evaporation comprises: the local temperature of the described part of described preliminary wax casting pattern is elevated to more than about 500 degrees Celsius; And the temperature of the adjacent part of described preliminary wax casting pattern is maintained lower than about 120 degrees Celsius; And after performing described laser ablation, scan the wax model of described transformation, to form the image of at least one additional features described.
Accompanying drawing with reference to forming this description part is below described, and accompanying drawing shows the concrete exemplary embodiment can implementing teaching of the present invention by way of illustration.These embodiments enough describe in detail, so that those skilled in the art can implement teaching of the present invention, and should be understood that and can utilize other embodiments, and can make a change when not deviating from the scope of teaching of the present invention.Therefore, following description is only illustrative.
Under the prerequisite of spirit and scope not departing from following claims, can explain relative to one or more embodiment and illustrated example be made a change and/or revised.In addition, although only with reference to the open special characteristic of the embodiment of in some embodiments, according to needs and the demand of any appointment or specific function, this feature can combine with other features one or more in other embodiments.In addition, if employ in detailed description of the invention and claims that term " comprises ", " comprising ", " containing ", " having ", " with " or its variant, be then similar to term and " comprise ", this type of term is inclusive implication.Term " ... at least one " is for representing that can to select in Listed Items one or more.
Although the number range and the parameter that define scope of embodiments are widely approximations, the numerical value in instantiation is all as far as possible accurately reported.But any numerical value may comprise standard deviation owing to existing in its respective thermometrically and the certain errors caused inherently.In addition, all scopes disclosed in this description are interpreted as any and all subranges of comprising wherein.Such as, the scope " being less than 10 " can comprise all and any subrange (comprising end value) between minimum value of zero and maximum 10, that is, minimum of a value be equal to or greater than zero and maximum be equal to or less than 10 any and all subranges, such as, 1 to 5.Under specific circumstances, the numerical value of parameter can be negative value.In this case, the example values of " being less than 10 " scope can comprise negative value, and such as-1 ,-2 ,-3 ,-10 ,-20 ,-30 etc.
Fig. 1 illustrates the schematic diagram of the system 2 for laser assisted casting according to the multiple embodiment of the present invention.As shown in the figure, system 2 can comprise laser system 4, described laser system is through programming to perform laser ablation to form the wax model 8 of transformation to preliminary wax casting pattern 6, the wax model 8 of described transformation comprises at least one additional features 10 non-existent in preliminary wax casting pattern 6.As described in this description, preliminary wax casting pattern 6 can comprise the wax material block of original, undressed or not other machining.Be shaped in the wax molding tool that preliminary wax casting pattern 6 is known in the art.System 2 can also comprise imaging system 12, for scanning the wax model 8 of transformation after performing laser ablation in laser system 4, to form the image of at least one additional features 10.In many embodiment:, imaging system 12 comprises at least one in two dimension (2D) scanning system or three-dimensional (3D) scanning system.System 2 may further include application system 26, for: a) the wax model 8 of coating transformation is (such as, use metallizing), to form the mold shape (or housing) of the wax model 8 around transformation, and b) remove the wax model 8 of transformation and leave casting mould 24 (also referred to as cast housing), described casting mould 24 comprises at least one additional features 10.System 2 can also comprise casting system 30, for pouring into a mould founding materials 32, to form shape (after the wax model 8 of confirmation transformation has desirable characteristics and forms casting mould 24) from casting mould 24.
In many embodiment:, system 2 can comprise the control system 20 being connected to laser system 4, application system 26, casting system 30 and/or imaging system 12.Control system 20 can be configured to provide instruction to laser system 4, application system 26, casting system 30 and/or imaging system 12 and/or control the operation of laser system 4, application system 26, casting system 30 and/or imaging system 12 in addition.Control system 20 mechanically or can be electrically connected to laser system 4, application system 26, casting system 30 and/or imaging system 12.Control system 20 can be to control the computerized device of laser system 4, application system 26, casting system 30 and/or imaging system 12, mechanical device or electromechanical assembly.In one embodiment, control system 20 can be the computerized device that can provide operational order to laser system 4, application system 26, casting system 30 and/or imaging system 12.In another embodiment, control system 20 can comprise the mechanical device that can be used by operator.In this case, operator can physical manipulation control system 20 (such as, passing through pull lever), its actuatable laser system 4, application system 26, casting system 30 and/or imaging system 12.In another embodiment, control system 20 can be electromechanical assembly.
Forward Fig. 2 to and continue with reference to figure 1, illustrated therein is the flow chart of the laser assisted casting method performed according to multiple embodiment.As shown in the figure, described method can comprise the following steps:
Step P1 (optional preprocessing): preliminary wax casting pattern is provided, such as, preliminary wax casting pattern 6 (Fig. 1).In many embodiment:, preliminary wax casting pattern 6 can comprise chloroflo, natural ester type waxes, synthetic wax, natural resin, synthetic resin, organic filler material, water and composition thereof.In a particular embodiment, preliminary wax casting pattern 6 can comprise aliphatic compound and (have the compound of carbons, such as, chloroflo, natural ester type waxes, synthetic wax and/or resin) or aromatic compound (there is the compound of ring structure carbon atom, filler and/or resin).
Step P2: perform laser ablation (using laser system 4) to form the casting pattern of transformation (such as to preliminary wax casting pattern 6, the casting pattern 8 of transformation), the casting pattern of described transformation comprises at least one additional features non-existent (such as, additional features 10) in preliminary wax casting pattern 6.As described in this description, the step performing laser ablation to preliminary wax casting pattern 6 can comprise and applies pulse laser (such as to preliminary wax casting pattern 6, ultra-short pulse laser), directly to evaporate a part 16 for preliminary wax casting pattern 6, form at least one additional features 10.The part 16 of evaporation is illustrated as the additional features 10 in the casting pattern 8 of transformation.In many embodiment:, direct evaporation step comprises the evaporating temperature local temperature of the part 16 of preliminary wax casting pattern 6 being increased above preliminary wax casting pattern 6, such as, about 500 degrees Celsius (in some cases, high to about 1,000 degree Celsius), the temperature of the adjacent part 18 of preliminary wax casting pattern 6 is maintained lower than its fusion temperature simultaneously, such as, about 120 degrees Celsius (in some cases, lower than about 50 degrees Celsius).
Step P3 (optional in certain embodiments): the casting pattern 8 (using imaging system 12) scanning transformation after performing laser ablation, to form the image of at least one additional features 10.In many embodiment:, described scanning comprises at least one in the 2D scanning or 3D scanning performing at least one additional features 10.
Step P4 (optional in certain embodiments): the described image based at least one additional features 10 described performs post laser ablation (using laser system 4) to the casting pattern 8 transformed.In many embodiment:, post laser assisted ablation step comprises the laser ablation methods of correction, and the laser ablation methods of described correction comprises at least one parameter relative to initial laser ablation parameters correction laser system 4, such as: a) laser power; B) laser spot; C) laser scanning speed; And/or d) laser pulse duration.According to imaging results and follow-up laser ablation, can repeated execution of steps P3 and P4, as shown in Figure 1.
In many embodiment:, other steps can comprise:
Step P5: the wax model 8 of coating transformation, to form mold shape (housing) 22.This can comprise and is deposited on the wax model 8 of transformation by lining material 21 (such as, metal), to form the mold shape (housing) 22 of the profile of the wax model 8 drawing transformation.
Step P6: the wax model 8 of removing transformation, and leave the casting mould 24 (housing) comprising at least one additional features 10.This can comprise, and such as, the wax model 8 transformed by physics and/or chemical depletion physically removes the wax model 8 of transformation.In some cases, by the wax model 8 of transformation being carried out prize, pulling, the wax model 8 of transformation removes from mold shape 22, and leaves the casting mould 24 of former state by torsion etc.In other cases, the wax model 8 of heating transformation until liquefaction (or evaporation), and is removed after heating.
Step P7: use the casting mould 24 with at least one additional features 10 to form shape by founding materials (such as, the such as metal such as steel or steel alloy) 32.Use the casting mould of transformation to form described shape by founding materials 32 can comprise: a) founding materials 32 is poured into and has in the casting mould 24 of at least one additional features 10; And b) cooling casting material 32 to solidify described shape.According to the specific nature of founding materials 32, process for cooling can comprise on one's own initiative that cooling casting material 32 is (such as, founding materials 32 is placed in cooler environment) or cooling casting material 32 (such as, allowing founding materials 32 at room temperature cool) passively.
Fig. 3 shows the process flow diagram of signal according to the technique in formation casting mould 24 of the multiple embodiment of the present invention.As shown in the figure: preliminary wax model 6 to form multiple feature 10 in described model, is formed the wax model 8 of transformation by laser ablation; Then form the casting mould 24 of the wax model around described transformation, reflect multiple feature 10; And in some techniques, by being poured into by founding materials in casting mould 24, also shifting out this material 32 from mould 24 subsequently forms component end item (such as, metal parts).
In many embodiment:, the parts being described as " connection " each other can engage along one or more interface.In certain embodiments, these interfaces can comprise the joint between different parts, and in other cases, these interfaces can comprise firmly and/or integrally formed POI.That is, in some cases, the parts of " connection " can be formed simultaneously each other, to define single continuous member.But in other embodiments, these parts connected can be shaped as independent component, then engaged by already known processes (such as, fastening, ultra-sonic welded, bonding).
Term used in this description, only for describing specific embodiment, is not intended to limit the present invention.Unless context separately explains, otherwise singulative used in this description " ", " one " and " described " are intended to comprise plural form simultaneously.Should understand further, term used in this description " comprise " and/or " comprising " for illustration of there are described feature, entirety, step, operation, element and/or parts, but do not get rid of exist or with the addition of other features one or more, entirety, step, operation, element, parts and/or its combination.Should be further understood that, term " front " and " afterwards " are not intended to limit, and expection is interchangeable in due course.
This description uses each example to open the present invention, comprises optimal mode, also allows any technical staff in affiliated field implement the present invention simultaneously, comprise and manufacture and use any device or system, and any method that enforcement is contained.Protection scope of the present invention is defined by claims, and can comprise other examples that one of ordinary skill in the art find out.If the structural element of other these type of examples is identical with the letter of claims, if or the letter of the equivalent structural elements that comprises of this type of example and claims without cardinal principle difference, then this type of example also belongs to the scope of claims.

Claims (20)

1. a method, described method comprises:
Perform laser ablation to preliminary wax casting pattern, to form the wax model of transformation, the wax model of described transformation comprises at least one additional features non-existent in described preliminary wax casting pattern;
Apply the wax model of described transformation, to form the mold shape of the wax model around described transformation; And
Remove the wax model of described transformation, and leave the casting mould comprising at least one additional features described.
2. method according to claim 1, it comprises further and uses the described casting mould with at least one additional features described to form shape by founding materials.
3. method according to claim 2, wherein said founding materials comprises steel or contains steel alloy.
4. method according to claim 2, the described shape of wherein said formation comprises:
Described founding materials is poured in the described casting mould with at least one additional features described; And
Cool described founding materials to solidify described shape.
5. method according to claim 1, the described laser ablation of wherein said execution comprises to described preliminary wax casting pattern applying ultra-short pulse laser, directly to evaporate a part for described preliminary wax casting pattern, forms at least one additional features described.
6. method according to claim 5, wherein said direct evaporation comprises the local temperature of the described part of described preliminary wax casting pattern is elevated to more than about 500 degrees Celsius.
7. method according to claim 6, wherein said direct evaporation comprises and maintains the temperature of the adjacent part of described preliminary wax casting pattern lower than about 120 degrees Celsius.
8. method according to claim 1, it scans the wax model of described transformation after being included in the described laser ablation of described execution further, to form the image of at least one additional features described.
9. method according to claim 8, wherein said scanning comprises at least one in the two-dimensional scan or 3-D scanning performing at least one additional features described.
10. method according to claim 9, its described image comprised further based at least one additional features described performs post laser ablation to the wax model of described transformation.
11. methods according to claim 10, wherein said post laser ablation comprises the laser ablation methods of correction, and the laser ablation methods of described correction comprises relative at least one item in the following item of described laser ablation correction: laser power, laser spot, laser scanning speed or laser pulse duration.
12. 1 kinds of systems, described system comprises:
Laser system, described laser system is through programming to perform to preliminary wax casting pattern the wax model that laser ablation forms transformation, and the wax model of described transformation comprises at least one additional features non-existent in described preliminary wax casting pattern;
Imaging system, for scanning the wax model of described transformation after performing described laser ablation, to form the image of at least one additional features described;
Application system, for applying the wax model of described transformation, to form the mold shape of the wax model around described transformation, and removes the wax model of described transformation, and leaves the casting mould comprising at least one additional features described; And
Casting system, casts shape for using the described casting mould with at least one additional features described by founding materials.
13. systems according to claim 12, wherein said imaging system comprises at least one in d scanning system or 3 D scanning system.
14. systems according to claim 12, wherein said laser system to perform described laser ablation by applying ultra-short pulse laser to described preliminary wax casting pattern with a part of directly evaporating described preliminary wax casting pattern, forms at least one additional features described through programming.
15. systems according to claim 14, wherein said direct evaporation comprises the local temperature of the described part of described preliminary wax casting pattern is elevated to more than about 500 degrees Celsius.
16. systems according to claim 15, wherein said direct evaporation comprises and maintains the temperature of the adjacent part of described preliminary wax casting pattern lower than about 120 degrees Celsius.
17. systems according to claim 12, wherein said laser system performs post laser ablation with the described image based at least one additional features described to the wax model of described transformation through programming further.
18. systems according to claim 17, wherein said post laser ablation comprises the laser ablation methods of correction, and the laser ablation methods of described correction comprises relative at least one item in item below described laser ablation correction: laser power, laser spot, laser scanning speed or laser pulse duration.
19. 1 kinds of methods, described method comprises:
Perform laser ablation to preliminary wax casting pattern, to form the wax model of transformation, the wax model of described transformation comprises at least one additional features non-existent in described preliminary wax casting pattern,
The described laser ablation of wherein said execution comprises to described preliminary wax casting pattern applying pulse laser, directly to evaporate a part for described preliminary wax casting pattern, forms at least one additional features described,
Wherein said direct evaporation comprises:
The local temperature of the described part of described preliminary wax casting pattern is elevated to more than about 500 degrees Celsius; And
The temperature of the adjacent part of described preliminary wax casting pattern is maintained lower than about 120 degrees Celsius; And
The wax model of described transformation is scanned, to form the image of at least one additional features described after performing described laser ablation.
20. methods according to claim 19, its described image comprised further based at least one additional features described performs post laser ablation to the wax model of described transformation, wherein said post laser ablation comprises the laser ablation methods of correction, the laser ablation methods of described correction comprises relative at least one item in the following item of described laser ablation correction: laser power, laser spot, laser scanning speed or laser pulse duration, wherein said pulse laser comprises ultra-short pulse laser.
CN201410641865.6A 2013-11-08 2014-11-07 Laser assisted casting and related system Pending CN104624962A (en)

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