CN109663888A - Method for mold kind crystalline substance - Google Patents
Method for mold kind crystalline substance Download PDFInfo
- Publication number
- CN109663888A CN109663888A CN201811196550.XA CN201811196550A CN109663888A CN 109663888 A CN109663888 A CN 109663888A CN 201811196550 A CN201811196550 A CN 201811196550A CN 109663888 A CN109663888 A CN 109663888A
- Authority
- CN
- China
- Prior art keywords
- jingjing
- mold
- ceramic
- jingjing body
- ceramic mold
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/02—Sand moulds or like moulds for shaped castings
- B22C9/04—Use of lost patterns
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D27/00—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting
- B22D27/20—Measures not previously mentioned for influencing the grain structure or texture; Selection of compositions therefor
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- C—CHEMISTRY; METALLURGY
- C30—CRYSTAL GROWTH
- C30B—SINGLE-CRYSTAL GROWTH; UNIDIRECTIONAL SOLIDIFICATION OF EUTECTIC MATERIAL OR UNIDIRECTIONAL DEMIXING OF EUTECTOID MATERIAL; REFINING BY ZONE-MELTING OF MATERIAL; PRODUCTION OF A HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; SINGLE CRYSTALS OR HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; AFTER-TREATMENT OF SINGLE CRYSTALS OR A HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; APPARATUS THEREFOR
- C30B11/00—Single-crystal growth by normal freezing or freezing under temperature gradient, e.g. Bridgman-Stockbarger method
- C30B11/002—Crucibles or containers for supporting the melt
-
- C—CHEMISTRY; METALLURGY
- C30—CRYSTAL GROWTH
- C30B—SINGLE-CRYSTAL GROWTH; UNIDIRECTIONAL SOLIDIFICATION OF EUTECTIC MATERIAL OR UNIDIRECTIONAL DEMIXING OF EUTECTOID MATERIAL; REFINING BY ZONE-MELTING OF MATERIAL; PRODUCTION OF A HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; SINGLE CRYSTALS OR HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; AFTER-TREATMENT OF SINGLE CRYSTALS OR A HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; APPARATUS THEREFOR
- C30B11/00—Single-crystal growth by normal freezing or freezing under temperature gradient, e.g. Bridgman-Stockbarger method
- C30B11/14—Single-crystal growth by normal freezing or freezing under temperature gradient, e.g. Bridgman-Stockbarger method characterised by the seed, e.g. its crystallographic orientation
-
- C—CHEMISTRY; METALLURGY
- C30—CRYSTAL GROWTH
- C30B—SINGLE-CRYSTAL GROWTH; UNIDIRECTIONAL SOLIDIFICATION OF EUTECTIC MATERIAL OR UNIDIRECTIONAL DEMIXING OF EUTECTOID MATERIAL; REFINING BY ZONE-MELTING OF MATERIAL; PRODUCTION OF A HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; SINGLE CRYSTALS OR HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; AFTER-TREATMENT OF SINGLE CRYSTALS OR A HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; APPARATUS THEREFOR
- C30B29/00—Single crystals or homogeneous polycrystalline material with defined structure characterised by the material or by their shape
- C30B29/02—Elements
Abstract
The present invention provides a kind of methods for producing cast member.This method includes being attached to ceramic mold on kind of Jingjing body, ceramic mold includes the chamber for limiting the shape of cast member, and kind Jingjing body interface, kind Jingjing body interface have the shape complementary with kind of Jingjing body, and kind Jingjing body is enabled to support the ceramic mold in foundry furnace.This method further includes pouring into liquid metal in mold, so that the brilliant part of kind facilitates the controlled crystallization of cast member.
Description
Technical field
The invention mainly relates to a kind of methods for mold kind brilliant (seeding), and relate more specifically to preheating
To the method for mold kind crystalline substance when mold is loaded into casting stove.Therefore, the present invention can be used in casting operation, e.g., superalloy
In casting, superalloy is used to make the turbo blade and stator vane of air injection aerial vehicle engine or power generating turbine component.
Background technique
Gas-turbine unit generally includes at least one compressor to pressurize and will import the air of burner.Engine can
Including at least one burner, wherein at least part of the forced air imported is mixed and is ignited with fuel.From compression
The hot gas of machine flows to downstream by least one turbine.Each turbine has rotating vane, the rotating vane
It encloses and rotates about the axis and contained in engine shell body.One or more turbines can be to any one in compressor, fan, axis
A energy supply, and/or thrust can be provided by passing through the expansion of nozzle.
Due to the power caused by high temperature and larger temperature fluctuation and the high revolving speed because being undergone during turbine normal operating, whirlpool
Turbo blade and/or stator vane in wheel part allow for tolerance thermal stress.It is high as turbine pressure ratio and efficiency increase
The thermal stress that pressure and low-pressure turbine portion are exposed to also increases.Therefore, in conjunction with by heat-resisting material manufacture turbine part (such as
Turbo blade and stator vane), effective cooling turbine bucket, stator vane and other components have become more and more important and have
Challenge.In order to resist the heat radiation and convection current to turbine, several removal techniques had been used in the past；Generally use fluid
The cooling service life to extend turbine part.In addition, small-sized cooling hole drills blade to remove heat and in turbine leaf to optimize angle
Thermal boundary is provided on the surface of each airfoil surface of piece and stator vane.Also channel is formed in turbine and/or stator vane
It is cooling with the convection current for providing each airfoil surface.
The internal cooling channel needed to have made in turbine part for increasing the cooling efficiency in turbogenerator complicates.With
It is related to model casting or wax-loss casting process in the routine techniques of manufacture engine part and component.One example of model casting
It is related to the typical blade that manufacture is used in gas-turbine unit.Turbo blade and/or stator vane generally include hollow airfoil
Part, has the radial groove extended along the span of blade, and the groove has at least one or more entrance to be used for
Pressurized cooling air is received during the operation of engine.Various cooling ducts in blade generally include to be placed in the middle part of airfoil
Sinuous groove between leading edge and rear.Airfoil generally includes to extend through blade for receiving pressurized cooling air
Entrance, the entrance include local feature, for example, short flow-disturbing rib or pin with for increasing airfoil heated side wall with it is interior
Heat transmitting between portion's cooling air.
The many as shown in Fig. 1 to 4 can be related to by usually manufacturing these turbo blades as high-intensitive superalloy metal material
Step.As shown in fig. 1, form cast member using traditional investment casting and generally include following steps: processing is for outside
Wax structure and punch die 101 for ceramic core；Mould and bake ceramic core 102；Mould the wax-pattern 103 with ceramic core；Wax group
Part preparation 104；Wax component is impregnated in 105 in ceramic slurry；Keep ceramic slurry dry to provide shell 106；Make shell dewaxing 107；
Casting and bleeding (leaching) 108；And bore cooling hole 109.
In above-mentioned technique, high technology ceramics core 200 is manufactured to meet desired sinuous cooling duct inside turbo blade.Also
Precision stamping die or mold are formed, the accurate 3D outer surface of turbo blade, including its airfoil, platform and whole wedge shape are limited
Tenon.Ceramic core 200 is assembled in inside two punch die half portions, and described two punch die half portions form the gained gold for limiting blade therebetween
Belong to the space or gap of part.The wax and/or plastics of relative stiffness are injected into the punch die of assembling to fill the gap and packet
Ceramic core 200 is enclosed, ceramic core 200 is encapsulated in wax here.Two punch die half portions are separated and removes with exposure and removes tool
There are the rigid wax and/or plastics of the accurate configuration of the wanted blade 211 formed by molding wax.Mould with packaging ceramic core 200
Wax blade 211 processed is next attached to wax tree structure (a wax tree structure) 212.Wax tree structure 212 is by solid paraffin
Or rigidity moulds the low any wax of wax of wax blade 211 and is formed than being used to form.It is melted since the wax of wax tree 212 will finally limit
Metal enters the flow path of ceramic mold, and the dimensional accuracy for being accordingly used in being formed the outer surface of the wax of tree construction 212 is less heavy
It wants.Therefore, compared with than wax blade precision modulding wax blade 211, compared with individual roads that soft wax is typically used to form wax tree 212
Diameter.Wax blade 211 needs pin 205 to hold the core in appropriate location.Tree construction 212 may include for adding molten metal to mould
The funnel shaped part 214 of tool.As shown in Figure 2 to 4, tree construction 212 further includes in casting operation for filtering molten metal
Ceramic filter 213.
After the wax injection and wax access 212 for forming wax tree structure are attached, entire wax tree structure 212, ceramic filter
213 and wax turbo blade 211 followed by ceramic material be coated with to form ceramic case 206,204 as shown in Figure 3.Then,
Wax melts and removes from ceramic case 206, to leave corresponding gap or sky between ceramic case 206 and inner ceramic core 200
Between 201,207.Once ceramic case 204 is just limited to be in fluid communication with gap or space 201,207 in addition, wax tree structure 212 is melted
Flow path.After removing wax, ceramic core is held in place by pin 205.As shown in Figure 4, superalloy is melted
Metal 208 is then poured into shell 206 by the flow path limited by a part of ceramic case 204.Melting superalloy can wrap
Include any one of following: stainless steel, aluminium, titanium, Inconel 625, Inconel 718, Inconel 188, cobalt chromium, nickel and
Other metal materials or any alloy；Such as nickel (Ni) superalloy and/or Ni superalloy single crystal alloy.For example, above-mentioned alloy can wrap
Include the material of following trade (brand) name: HaynesHaynesSuper Alloy Inconel 625TM、625、625、625、6020,188 Inconel, and tool
Be conducive to any other material of the material property using technology forming member mentioned above.Molten metal 208 fills sky
Gap 201,207 and encapsulation are contained in the ceramic core 200 in shell 206.Keep molten metal 208 cooling and solidify, and then suitably moves
Except external ceramic case 206 and inner ceramic core 200, to retain the wanted metal worm leaf that wherein there is internal cooling channel
Piece.In order to provide path for removing ceramic core material by leaching technique, it is possible to provide ball skewed slot (not shown) and tip
Sell (not shown).Generally speaking, after leaching technique, ball skewed slot and tip pin hole in turbo blade must be then brazed
It closes.
Casting turbo blade 208 is modified after usually carrying out additional casting, such as is optionally drilled out through airfoil side wall
The film-cooling hole of appropriate rows is with the outlet of the cooling air for providing internal importing, and the cooling air is then in combustion gas whirlpool
(commonly referred to as film is cold for formation protection cooling air film or layer on the outer surface of airfoil during operation in turbine
But).In turbo blade after ceramic mold removal, the pin 205 of ceramic core 200 is kept to form the access that can be brazed closing later
To provide the wanted air path of the internal voids across casting turbo blade.It is limited however, being modified after these castings, and
Complexity in turbogenerator constantly increase and turbo blade inside efficiency improvement is generally acknowledged provided by certain cooling circuits
In the case where, need more complicated interior geometry.Although investment casting can manufacture these components, make
It is manufactured with these manufacturing processes customaries so that position precision and complicated interior geometry become more sophisticated, and
Therefore manufacturing time and expense are dramatically increased.Therefore, it is necessary to be the three-dimensional with complicated internal voids and cooling circuit
Component provides a kind of improved casting method.
Increases material manufacturing technology and 3D printing allow in tool path associated not with material manufacture is subtracted and/or molding limitation
In the case where manufacture mold.For example, the 8th of Rools-Royce (Rolls-Royce Corporation) is transferred,
It is described in No. 851,151 United States Patent (USP)s using 3D printing to generate ceramic core-shell mold tool method.For making the side of mold
Method includes such as transferring No. 5,387,380 United States Patent (USP) of Massachusetts Institute of Technology
Disclosed powder bed ceramic process, and 3D Systems is such as transferred, it is public in the 5th, 256, No. 340 United States Patent (USP) of Inc
The selective laser activation (SLA) opened.According to the ceramic core of ' 151 patents-shell mold tool by the print resolution ability of these techniques
It limits significantly.As shown in Figure 5, the core segment 301 of integrated core-shell mold 300 and shell parts 302 pass through mold 300
A series of connection structures 303 provided at bottom margin keep together.The cooling duct proposed in ' 151 patents includes logical
The staggering vertical chamber of too short cylinder engagement, the short column body length are almost the same with its diameter.Then it uses public in ' 151 patents
Known technology that is opening and being incorporated herein by way of introduction forms superalloy turbo blade in core-shell mold.At these
After casting turbo blade in one in core-shell mold, mold is removed to appear the superalloy turbo blade of casting.
Fig. 6 shows the method for mold kind described in ' 151 patents brilliant (seeding a mold).Mold 605, which has, to be used
In the inner chamber 606 for receiving molten metal.Mold 605 has ventilation end 607, and it is logical to travel to and fro between inner chamber 606 for gaseous material
It crosses, and for receiving the starting kind crystalline substance reception entrance 609 with jointing metal starting kind crystalline substance (starter seed) 608.Metal
Starting kind crystalline substance 608, which is positioned on the 608a of surface, receives molten metal.The brilliant auxiliary heater 615 of starting kind and supplement mold heating
Device 616 is located in mold 605.Thermal break 610 is located between the lower surface 605a of mold 605 and heat-transfer devices 611, with most
Heat transmitting of smallization from casting mould 605.Heat-transfer devices 611 include a pair of of arm 613 and 614, be can be moved into and starting kind
The surface 618 of crystalline substance 608 against and the position that is kept in contact.Heat-transfer devices 611 and starting kind crystalline substance 608 can be maintained against pass
System, until arm 613 and 614 is initiatively discharged from starting kind crystalline substance 608.It is accurately positioned the bottom surface of the contact starting kind of component 612 crystalline substance 608
608b, so that the vertical height of bath surface 608a to be positioned accurately in molten metal receiving cavity 606.Cooling medium access
617 are formed in each of a pair of of arm 613 and 614, for making cooling medium by therebetween.Melting gold in chamber 605
Category transfers heat to starting kind crystalline substance 608, and starting kind crystalline substance 608 is transferred to cooling a pair of of arm 613 via surface 618 after and by heat
With 614.The cooling medium for flowing through access 617 removes heat from arm 613 and 614.Therefore, the temperature across starting kind crystalline substance 608 is produced
Gradient is spent, to cause the directional solidification of the molten metal in chamber 606.
Summary of the invention
Following present the brief overviews of the one or more aspects of present disclosure, in order to provide basic reason in this respect
Solution.This is summarized and the extensive overview of not all contemplated aspects, and is both not intended to indicate crucial or decisive element in all aspects,
Also it is not intended to delimit the range in terms of any or all.Its object is to show some of one or more aspects in simplified form
Concept, to draw more detailed description presented below.
Aforementioned and/or other aspects of the invention can be realized by producing the method for cast member.This method includes will
Ceramic mold is attached on kind of Jingjing body, and ceramic mold includes the chamber for limiting the shape of cast member, and plants Jingjing body interface,
Kind Jingjing body interface has the shape complementary with kind of Jingjing body, and kind Jingjing body is enabled to support the ceramic mold in foundry furnace.
This method further includes pouring into liquid metal in mold, so that the brilliant part of kind facilitates the controlled crystallization of cast member.
On the one hand, the kind Jingjing body interface of ceramic mold has funnel shaped, and plants Jingjing body with cone shape.
On the other hand, kind Jingjing body can be attached to the pedestal branch in foundry furnace when ceramic mold is attached on kind of Jingjing body
In bearing member.
Another aspect, ceramic mold could attach on kind of a Jingjing body (seed crystal body), and the cladding of ceramics applies
Layer (overcoat) can be applied at least part of ceramic mold and kind Jingjing body, to form cast assembly, and be cast
Component can be fixed in foundry furnace before toppling over liquid metal.
On the other hand, cast assembly can be fixed in foundry furnace by the attachment mechanism on kind of Jingjing body.
On the other hand, kind Jingjing body can be single type single-crystal metal (one-piece single crystal metal),
It has for that will plant the attachment mechanism that Jingjing body is fixed in foundry furnace.
Another aspect, the kind Jingjing body interface of casting mould include that the alignment feature of Jingjing body is corresponding is aligned spy with kind
Sign, with the crystal orientation for controlling the cast member in casting mould.
Another aspect, ceramic mold include channel, and channel deviates kind of Jingjing body interface from the chamber of ceramic mold.
Aforementioned and/or other aspects of the invention can be realized by producing the ceramic mold of cast member.On the one hand, it makes pottery
Porcelain mold include limit cast member shape chamber, with the shape complementary with kind of Jingjing body kind of a Jingjing body is supported
The kind Jingjing body interface of ceramic mold in foundry furnace, and it is corresponding with kind of the alignment feature of Jingjing body for controlling casting die
The alignment feature of the crystal orientation of cast member in tool.
On the one hand, the kind Jingjing body interface of ceramic mold can have funnel shaped corresponding with the cone shape for planting Jingjing body
On the other hand, ceramic mold includes channel, and channel deviates kind of Jingjing body interface from the chamber of ceramic mold.
Aforementioned and/or other aspects of the invention can be realized by producing the cast assembly of cast member.Cast assembly
Including ceramic mold, ceramic mold includes the chamber for limiting the shape of kind of Jingjing body interface and cast member；Kind Jingjing body, plants Jingjing
Body interface has the shape complementary with kind of Jingjing body；And at least one ceramic coatings coating, the coating cover ceramic die
At least part of tool and kind Jingjing body is to form cast assembly.
On the one hand, cast assembly may also include the attachment machine on the kind Jingjing body for the kind Jingjing body in fixed cast furnace
Structure.
On the other hand, kind Jingjing body is single type single-crystal metal, has and is fixed in foundry furnace for that will plant Jingjing body
Attachment mechanism.
According to following detailed descriptions, drawings and claims, other feature and aspect can be obvious.
Detailed description of the invention
One or more instance aspects that part thereof of attached drawing shows the disclosure are incorporated in this specification and constitute, and even
With detailed description together for explaining its principle and embodiment.
Fig. 1 is block diagram the step of showing conventional model casting；
Fig. 2 is the signal for showing the conventional wax pattern of the model casting for turbo blade being attached in wax tree structure
Figure；
Fig. 3 is the schematic diagram for showing the conventional ceramic mold of Fig. 2 after having removed wax；
Fig. 4 is the schematic diagram for showing the conventional ceramic mold of Fig. 2 after pouring into molten metal in mold；
Fig. 5 is to show the perspective view with connection core core-shell mold integrated with the prior art of the connector of shell parts
Schematic diagram；
Fig. 6 is the schematic diagram for the prior art device for having the starting kind in casting mould brilliant；
Fig. 7 A and 7B are the cross section side views of the ceramic mold for showing embodiment according to the present invention and crystal growth structure
The schematic diagram of figure；
Fig. 8 is the block diagram for showing the casting process of embodiment according to the present invention；And
Fig. 9 A and 9B are show ceramic mold and crystal growth structure according to another embodiment of the invention transversal
The schematic diagram of surface side view.
Specific embodiment
The following detailed description of the drawings is intended as the description of various constructions, and is not intended to indicate to practice herein
The unique configuration of described concept.Detailed description includes being intended to provide the detail of the thorough understanding to each conception of species.So
And to those of ordinary skill in the art it is readily apparent that can practice without these specific details
These concepts.For example, the present invention provides a kind of preferred method to manufacture cast metallic parts, and is preferably used in jet
Cast metallic parts those of in the manufacture of formula aircraft engine.Exactly, it can carry out advantageously, according to the present invention such as
The production of turbo blade, the monocrystalline of wheel blade and shield part, nickel based super alloy mo(u)lded piece.However, skill of the invention can be used
Art and integrated ceramic mold prepare other casting metal components.
In general, monocrystalline mold needs kind of a crystalline substance, but common method leads to the crystalline state of the kind of additional step or compromise.Monocrystalline mold
Usually kind is brilliant in two ways.A kind of conventional method is metal kind crystalline substance to be placed on wax component and in its shell, so that kind is brilliant
It is integrated into mold.Another conventional method is to be integrated to kind of crystalline substance after ceramic mold firing to be shaped to kind of a chamber for brilliant negative film
In.The first aspect of the present invention is related to brilliant to mold kind when preheated mold is loaded into casting stove.By generating normal casting
The brilliant part of the kind of step (that is, being loaded into stove), the present invention can reduce defect associated with typical method, for example, such as, mold with
Kind crystalline substance oxidation in the brilliant firing of kind, or casting introduce field trash by being integrated in kind of crystalline substance before.
Fig. 7 A is the schematic diagram of the ceramic mold for showing embodiment according to the present invention and the side view of crystal growth structure.
As shown in Figure 7A, if core 700 can be connected on shell 701 by shredded dried bean curd 702.Core 700 and shell 701 form core-shell mold 700/
701, limit the chamber 703 for being used for model casting turbo blade.The bottom part of core-shell mold 700/701 may be configured to have
Funnel shaped corresponding with ceramic circular cone 710.According on one side, core-shell mold 700/701 can be configured to kind of Jingjing body circle
Face, to adapt to ceramic circular cone 710, so that core-shell mold 700/701 fits closely on ceramic circular cone 710.Core-shell mold
700/701 may be configured to interface, and with alignment feature, alignment feature is corresponding with the ceramic alignment feature of circular cone 710 at interface,
So that available core-shell mold 700/701 controls the crystal orientation of resulting cast member.In attachment, ceramic 710 He of circular cone
Core-shell mold 700/701 can form the cast assembly being placed on support plate 718.Support plate 718 may be configured to screw
716.The bottom part of ceramic circular cone 710 may be configured to attachment mechanism 714, to be located on support plate 718 for receiving
Screw 716.The top section of ceramic circular cone 710 may include the kind crystalline substance 712 for solidifying liquid metal, this is discussed below.
Although ceramic circular cone 710 and kind crystalline substance 712 are described as individual component by the present invention, the present invention can be without being limited thereto.
In another exemplary embodiment, ceramic circular cone and kind crystalline substance can be configured to single-crystal metal growth part to fit into ceramic mold.
Single-crystal metal growth part limits the kind Jingjing body for being configured to matching kind Jingjing body interface.Invention further describes core-shell molds
700/701 bottom part has funnel shaped corresponding with the ceramic circular cone 710 of triangle-cone, but can be without being limited thereto.
The funnel shaped of the bottom part of core-shell mold 700/701 is spaced apart by channel 711 with chamber 703.In this regard, core-shell mold
700/701 bottom part is fluidly connected on chamber 703 by channel 711, and channel 711 is configured to make bottom part from chamber 703
Offset.In other exemplary embodiments of the invention, the construction of the bottom part of core-shell mold 700/701 and ceramic circular cone 710 can be each
Kind of other shapes, e.g., pyramid and correspond to each other, and the bottom part of core-shell mold is allowed to adapt to and fit closely to
On ceramic circular cone.
Fig. 7 B is the diagram of preferred illustrative embodiment, and wherein support plate 718 is configured to keep having to be attached to thereon
The ceramic circular cone 710 of core-shell mold 700/701.The top section of core-shell mold 700/701 may be configured to have for that will melt
Melt the channel that metal pours into inner cavity 703.
Fig. 8 is the block diagram for showing the casting process of embodiment according to the present invention.(DLP) work is printed by using direct light
Skill or any other increasing material manufacturing method having to form ceramic core-shell mold, the manufacture of component are needed than typical model casting
Significant less step.Fig. 8 shows following steps: forming ceramic mold and core 801 using increasing material manufacturing, prepares wax component
802, ceramics coating 803, dry slurry 804, dewaxing and/or sintering procedure 805, and cast and leach ceramic material 806.It can
Recognize, ceramics coating 803 can repeat as shown in Figure 8 with the step of dry slurry 804.The above-mentioned technique for forming mold can wrap
It includes and forms ceramic mold and core using DLP technique, so that mold is formed as core-shell structure and by the first photopolymerizable ceramic material
It is formed.Mold once being formed, then mold in conjunction with several molds and/or can be added with wax part 802, and the wax part is by shape
At the flow path for melted material.Core-shell mold and any additional wax structure previously added can then carry out dipping or
Coating process 803 is applied with forming ceramics on the outer surface of the shell of core-shell mold and on the outer surface of any wax structure of addition
Layer.Technique can be dried then to dry slurry 804 in core-shell mold.As mentioned above, step 803 and 804 is repeated.
Then, core-shell mold and outer ceramic case can be dewaxed and/or be baked technique 805 to remove wax and/or sintering and form the mould
The ceramic material of tool.It is to be understood that if ceramic mold and core in step 801 are made into final mold shape and are ready to incline
, then can be omitted step 802,803,804 and 805.Then molten metal can be poured into mold.Once it is metal-cured,
Core-shell mold and shell can be removed by leaching ceramic material and/or removing mold by machinery.
Fig. 9 A and 9B are show ceramic mold and crystal growth structure according to another embodiment of the invention transversal
The schematic diagram of surface side view.In figure 9 a, the first outer ceramic layer 904 may be formed at core/shell mold tool 900/901 outer boundary.
For example, the first outer ceramic layer 904 can be formed by the technique for immersing core-shell mold in ceramic slurry.According on one side,
For example, outer ceramic layer is formed as single layer, the single layer by core-shell mold by immersing in ceramic slurry, doing slurry
It is dry and immerse core-shell mold in identical ceramic slurry and/or different types of slurry to form shell on core-shell mold
To be formed.Ceramic layer can provide architecture quality for core-shell mold, serve as the durability of the core-shell mold for increasing cladding
Reinforcer, and the thermal property of mold can be improved.Fire resisting crystal grain can be sieved on the slurry coating being spread between layer.It should be noted that can replace
In generation, comes in conjunction with impregnation technology referred to above using the other forms for forming ceramic coating.For example, can by ceramics and/
Or other materials are sprayed onto core-shell.For example, slurry mentioned above may include colloidal silicon dioxide and ceramic powder
(such as Al2O3, SiO2, ZrSiO4, ZrO2, Y2O3, AIN, SiC).Above-mentioned crystal grain can apply between layers and can wrap
Include the ceramic sand (such as Al2O3, SiO2, ZrSiO4, ZrO2, Y2O3, AIN, SiC) of 90 to 120 mesh.Subsequent slurry can be coated
Layer, and 20 to 70 mesh and/or the subsequent ceramic layer of sand of 10 to 30 purposes can be coated.Once forming necessary outer layer in core-shell, just
Mold can be baked with agglomerated material；Hereafter, any of above metal (such as superalloy) can be poured into mold.
According to exemplary embodiment as shown in Figure 9A and 9B, the second outer ceramic layer 920 may be formed at ceramic layer 904
At outer boundary.In this regard, core-shell mold 900/901, with positioning on top of this kind crystalline substance 912 ceramic circular cone 910,
Ceramic layer 904 and the second outer ceramic layer 920 can provide as single cast assembly, to be placed on support plate 918 and be then subsequently loaded into casting
It makes in stove (not shown).Second outer ceramic layer 920 can be made of material and be configured with similar with ceramic circular cone 910
Hot expansion property.In this way, can avoid the cracking or unwanted stress from the heat generated during casting.It makes pottery outside using second
In the case where enamel coating 920, outer layer can increase the intensity of entire mold, and/or modulate the thermal property of mold.
According to exemplary embodiments described above, kind crystalline substance can be connect with the cavity fluid of ceramic mold, and be filled with liquid
State metal.When liquid metal pours into inner cavity, crystal starts to grow in upward direction at kind of crystalline substance, to generate cured casting
Object.It will be appreciated by those skilled in the art that kind crystals growth structure according to the present exemplary embodiment is usually not to be taken as greatly
The support of the ceramic mold of cooling support plate is placed on body.Once liquid metal hardens, then ceramic core and shell can be leached.It is dripping
When out, resulting casting object can be turbo blade.
According to embodiment described above, the present invention provides unique timing, it is included in and mold is loaded into casting stove
Insertion kind is brilliant when middle, this is generally impractical when using Multi-part molds.According on one side, before casting, can minimize
Kind of crystalline substance is exposed to raising temperature, and plant brilliant oxidation can be reduced and/or eliminate (for example, be different from conventional method, wherein mould
Tool when being placed in wax fire or combine when outside preheat).The present invention is also convenient for being downloaded into mold in raised firing temperature,
Because kind crystalline substance need not combine, to eliminate mold thermal cycle.It is directly loaded into for example, mold can be fired from mold；Equally, it prints
Mold can also from core fire be directly loaded into.
This written description discloses the present invention, including preferred embodiment using example, and also makes the skill of fields
Art personnel can practice the present invention, including manufacturing and using any device or system and executing any method being incorporated to.This hair
Bright patentable scope is defined by the claims, and may include that those skilled in the art is expected other shows
Example.If other such examples have structural detail identical with the literal language of claims, or if they include
Literal language with claims is without the equivalent structural elements of essential difference, then other such examples are wished in claim
In the range of book.Other known equivalents of aspect and each such aspect from described various embodiments can be by
One of ordinary skill in the art are mixed and matched to construct Additional embodiments and technology according to the principle of the application.
Claims (10)
1. a kind of method for producing cast member, comprising:
Ceramic mold is attached on kind of Jingjing body, the ceramic mold include the shape for limiting the cast member chamber and
Kind Jingjing body interface, described kind of Jingjing body interface has the shape complementary with described kind of Jingjing body, so that described kind of Jingjing physical efficiency
Enough support the ceramic mold in foundry furnace；And
Liquid metal is poured into the mold, so that the brilliant part of kind facilitates the controlled crystallization of the cast member.
2. according to the method described in claim 1, wherein the kind Jingjing body interface of the ceramic mold have funnel shaped, and
Described kind of Jingjing body has cone shape.
3. according to the method described in claim 1, wherein described kind of Jingjing body in the ceramic mold is attached to described kind of Jingjing
It is attached to when on body in the base support in the foundry furnace.
4. according to the method described in claim 1, wherein the ceramic mold is attached on described kind of Jingjing body, and the packet of ceramics
Coating is covered to be applied at least part of the ceramic mold and described kind of Jingjing body, to form cast assembly, and it is described
Cast assembly is fixed in the foundry furnace before toppling over the liquid metal.
5. according to the method described in claim 4, wherein the cast assembly is solid by the attachment mechanism on described kind of Jingjing body
It is scheduled in the foundry furnace.
6. according to the method described in claim 1, wherein described kind of Jingjing body is single type single-crystal metal, the single type monocrystalline
Metal has the attachment mechanism for being fixed on described kind of Jingjing body in the foundry furnace.
7. according to the method described in claim 1, wherein the kind Jingjing body interface of the casting mould includes and described kind of Jingjing
The corresponding alignment feature of the alignment feature of body, with the crystal orientation for controlling the cast member in the casting mould.
8. the channel is configured to make described kind according to the method described in claim 1, wherein the ceramic mold includes channel
Jingjing body interface is deviated from the chamber of the ceramic mold.
9. a kind of for producing the ceramic mold of cast member, comprising:
Limit the chamber of the shape of the cast member；
Kind Jingjing body interface, described kind of Jingjing body interface has the shape complementary with kind of Jingjing body, so that described kind of Jingjing physical efficiency
Enough support the ceramic mold in foundry furnace；And
Alignment feature corresponding with the alignment feature of described kind of Jingjing body, for controlling the cast member in the casting mould
Crystal orientation.
10. a kind of for producing the cast assembly of cast member, comprising:
Ceramic mold, the ceramic mold include the chamber for limiting the shape of the cast member, and kind Jingjing body interface；
Kind Jingjing body, described kind of Jingjing body interface have the shape complementary with described kind of Jingjing body；And
At least one ceramic coatings coating, at least one described ceramic coatings coating cover the ceramic mold and described kind of Jingjing
At least part of body, to form the cast assembly.
Applications Claiming Priority (4)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US201762572781P | 2017-10-16 | 2017-10-16 | |
| US62/572,781 | 2017-10-16 | ||
| US15/995,931 US11014153B2 (en) | 2017-10-23 | 2018-06-01 | Method for seeding a mold |
| US15/995,931 | 2018-06-01 |
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| Publication Number | Publication Date |
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| CN109663888A true CN109663888A (en) | 2019-04-23 |
| CN109663888B CN109663888B (en) | 2021-07-30 |
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| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN201811196550.XA Active CN109663888B (en) | 2017-10-16 | 2018-10-15 | Method for mold seeding |
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN114273610A (en) * | 2021-12-01 | 2022-04-05 | 东方电气集团东方汽轮机有限公司 | Shell for investment casting of directional crystallization blade and preparation method |
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|---|---|
| CN109663888B (en) | 2021-07-30 |
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