EP0479672A1 - Soluble shell mould for foundry and method for disposal - Google Patents

Soluble shell mould for foundry and method for disposal Download PDF

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Publication number
EP0479672A1
EP0479672A1 EP91402625A EP91402625A EP0479672A1 EP 0479672 A1 EP0479672 A1 EP 0479672A1 EP 91402625 A EP91402625 A EP 91402625A EP 91402625 A EP91402625 A EP 91402625A EP 0479672 A1 EP0479672 A1 EP 0479672A1
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EP
European Patent Office
Prior art keywords
zircon
shell mold
flour
slip
fused silica
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.)
Granted
Application number
EP91402625A
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German (de)
French (fr)
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EP0479672B1 (en
Inventor
Thierry André Cuisin
Vincent Raymond Jacques Poirier
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Safran Aircraft Engines SAS
Original Assignee
Societe Nationale dEtude et de Construction de Moteurs dAviation SNECMA
SNECMA SAS
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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C1/00—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds
    • B22C1/16—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by the use of binding agents; Mixtures of binding agents
    • B22C1/165—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by the use of binding agents; Mixtures of binding agents in the manufacture of multilayered shell moulds
    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D29/00—Removing castings from moulds, not restricted to casting processes covered by a single main group; Removing cores; Handling ingots

Definitions

  • the present invention relates to a shell mold for foundries, the composition of which provides properties facilitating the elimination after casting of the parts, in particular in foundry processes of the lost wax type.
  • slip compositions used for the manufacture of foundry shell molds have in particular been described by EP-A-0 251 847, US-A-3 249 972, FR-A-2 348 772.
  • a mold-shell for foundries meeting these conditions and allowing in particular improved conditions for eliminating the mold after casting of the parts is characterized in that it is obtained from slips based on a binder product of the colloidal silica type or of the ethyl silicate type and of a ceramic mineral filler whose composition in percentages of dry mass comprises between 70 and 95% of fused silica and between 5 and 30% of zircon.
  • This method of obtaining the shell mold results in a final composition, in percentage of dry mass, of 70% of fused silica and 30% of zircon.
  • the percentages of dry mass can vary in the proportions between fused silica which remains the majority element and zircon.
  • the final composition, in percentages of dry mass is 95% of fused silica and 5% of zircon. It should therefore be noted that these percentages can vary between 70 and 95% of fused silica and between 5 and 30% of zircon.
  • This last step (c) of dissolution which characterizes the invention can in particular be implemented using an autoclave and a soda bath, under average conditions of temperature and pressure of 200 ° C. and 1.5 MPa.

Abstract

A shell mould which can be used in lost-wax foundry is obtained from slips based on a binder of the colloidal silica or ethyl silicate type and from a ceramic inorganic filler based on fused silica and zircon, giving rise to a composition expressed as a percentage of dry mass comprising 70 to 95 % of fused silica and 5 to 30 % of zircon. The method for disposal comprises dissolution in a basic bath.

Description

La présente invention concerne un moule-carapace pour fonderie dont la composition procure des propriétés facilitant l'élimination après coulée des pièces, notamment dans les procédés de fonderie du type à cire perdue.The present invention relates to a shell mold for foundries, the composition of which provides properties facilitating the elimination after casting of the parts, in particular in foundry processes of the lost wax type.

Elle concerne également un procédé d'élimination dudit moule-carapace.It also relates to a process for eliminating said shell mold.

Comme il est déjà bien connu, les procédés de fonderie utilisant des moules-carapaces en céramique comportent notamment les étapes suivantes :

  • - réalisation d'un modèle, généralement en cire, de la pièce à réaliser,
  • - enrobage du modèle par couches successives à partir de barbotines de compositions déterminées avec séchages intermédiaires, de manière à former ledit moule-carapace,
  • - traitement thermique ou cuisson selon des cycles déterminés de températures et durées de manière à obtenir une consolidation ou "cuisson" du moule et l'élimination du modèle,
  • - réalisation d'une opération de coulée de pièce dans le moule obtenu qui peut par exemple avoir la forme d'une "grappe" dans le cas d'une coulée simultanée de plusieurs pièces, notamment pour des applications aéronautiques telles que des aubes de moteur, particulièrement visées par l'invention,
  • - élimination du moule-carapace.
As is already well known, foundry processes using ceramic shell molds include the following steps:
  • - production of a model, generally in wax, of the part to be produced,
  • - coating of the model in successive layers from slips of determined compositions with intermediate drying, so as to form said shell mold,
  • - heat treatment or cooking according to determined cycles of temperatures and times so as to obtain a consolidation or "cooking" of the mold and the elimination of the model,
  • - Carrying out a part casting operation in the mold obtained, which can for example have the form of a "cluster" in the case of a simultaneous casting of several parts, in particular for aeronautical applications such as engine blades , particularly targeted by the invention,
  • - elimination of the shell mold.

Cette dernière opération fait habituellement appel à des techniques connues de décochage mécanique puis de grenaillage et de sablage. Certaines difficultés mal résolues ont toutefois été rencontrées. Pour certaines pièces de forme complexe, présentant notamment des cavités ou des coudes, ces opérations sont insuffisantes pour éliminer la carapace dans les zones enfermées. En outre certaines pièces, telles que des roues de compresseur de conception monobloc ayant des pales à épaisseur de toiles très faible, présentent des parties très fragiles qui risquent d'être endommagées ou cassées lors d'un décochage mécanique. Enfin, les pièces à structure mono- cristalline ne doivent pas subir de chocs pendant toutes les opérations de parachèvement afin d'éviter l'apparition de phénomènes de recristallisation.This last operation usually uses known techniques of mechanical release then shot blasting and sandblasting. However, some poorly resolved difficulties were encountered. For certain pieces of complex shape, in particular having cavities or elbows, these operations are insufficient to eliminate the shell in the enclosed areas. In addition, certain parts, such as compressor wheels of monobloc design having blades with very small fabric thickness, have very fragile parts which risk being damaged or broken during a mechanical release. Finally, the parts with a monocrystalline structure must not be subjected to impacts during all the finishing operations in order to avoid the appearance of recrystallization phenomena.

Par ailleurs, des exemples de compositions de barbotines utilisées pour la fabrication de moules-carapaces de fonderie ont notamment été décrits par EP-A-0 251 847, US-A-3 249 972, FR-A-2 348 772.Furthermore, examples of slip compositions used for the manufacture of foundry shell molds have in particular been described by EP-A-0 251 847, US-A-3 249 972, FR-A-2 348 772.

Ces compositions connues ne résolvent cependant pas entièrement tous les problèmes d'élimination du moule-carapace qui ont été notés ci-dessus.These known compositions do not however entirely resolve all of the problems of elimination of the shell mold which have been noted above.

Un moule-carapace pour fonderie répondant à ces conditions et permettant notamment des conditions améliorées d'élimination du moule après coulée des pièces est caractérisé en ce qu'il est obtenu à partir de barbotines à base d'un produit liant du type silice colloïdale ou du type silicate d'éthyle et d'une charge minérale céramique dont la composition en pourcentages de masse sèche comprend entre 70 et 95 % de silice fondue et entre 5 et 30 % de zircon.A mold-shell for foundries meeting these conditions and allowing in particular improved conditions for eliminating the mold after casting of the parts is characterized in that it is obtained from slips based on a binder product of the colloidal silica type or of the ethyl silicate type and of a ceramic mineral filler whose composition in percentages of dry mass comprises between 70 and 95% of fused silica and between 5 and 30% of zircon.

Un procédé remarquable d'élimination dudit moule-carapace après coulée des pièces est caractérisé en ce qu'il comporte les étapes suivantes :

  • - (a) élimination manuelle partielle du moule-carapace ;
  • - (b) découpe des pièces coulées ;
  • - (c) dissolution complète du moule-carapace en
A remarkable process for removing said shell mold after casting the parts is characterized in that it comprises the following steps:
  • - (a) partial manual elimination of the shell mold;
  • - (b) cutting of the castings;
  • - (c) complete dissolution of the shell mold in

bain basique à base de soude ou de potasse. D'autres caractéristiques et avantages de l'invention seront mieux compris à la lecture de la description qui va suivre d'exemples non limitatifs de réalisation illustrant l'invention.basic bath based on soda or potash. Other characteristics and advantages of the invention will be better understood on reading the description which follows of nonlimiting exemplary embodiments illustrating the invention.

EXEMPLE 1EXAMPLE 1

Un moule-carapace pourfonderie à la cire perdue conforme à l'invention et ayant une composition spécialement adaptée pour permettre une élimination par dissolution chimique après coulée de pièces et possédant par conséquent des propriétés remarquables de solubilité peut être obtenu par des opérations successives et répétées un nombre de fois convenant au résultat recherché, selon des techniques connues en soi, de trempé du modèle en cire puis de séchage, dans des barbotines dont les compositions remarquables et conformes à l'invention sont les suivantes dans le présent exemple :

  • - première barbotine de contact comprenant :
    • 20 % de silice colloïdale,
    • 79 % de farine de zircon,
    • 1 % d'un agent complémentaire à propriétés mouillantes et anti-mousse.
  • - puis une deuxième barbotine de contact, comprenant :
    • 25 % de silice colloïdale,
    • 49 % de farine de zircon,
    • 25 % de farine de silice fondue,
    • 1 % d'un agent complémentaire à propriétés mouillantes et anti mousse.
  • - et enfin une barbotine de renfort, comprenant :
    • 20 % de silice colloïdale,
    • 33 % de farine de zircon,
    • 42 % de silice fondue
    • 3 % de farine de cristobalite,
    • 2 % d'un agent complémentaire de suspension.
A shell mold for lost wax casting in accordance with the invention and having a composition specially adapted to allow elimination by chemical dissolution after casting of parts and consequently having remarkable solubility properties can be obtained by successive and repeated operations. number of times suitable for the desired result, according to techniques known per se, of dipping the wax model and then drying, in slips of which the remarkable compositions and in accordance with the invention are the following in the present example:
  • - first contact slip comprising:
    • 20% colloidal silica,
    • 79% zircon flour,
    • 1% of an additional agent with wetting and anti-foaming properties.
  • - then a second contact slip, comprising:
    • 25% colloidal silica,
    • 49% zircon flour,
    • 25% melted silica flour,
    • 1% of an additional agent with wetting and anti-foaming properties.
  • - and finally a reinforcing slip, comprising:
    • 20% colloidal silica,
    • 33% zircon flour,
    • 42% fused silica
    • 3% cristobalite flour,
    • 2% of an additional suspension agent.

Ce mode d'obtention du moule-carapace conduit à une composition finale, en pourcentage de masse sèche, de 70 % de silice fondue et 30 % de zircon.This method of obtaining the shell mold results in a final composition, in percentage of dry mass, of 70% of fused silica and 30% of zircon.

AUTRES EXEMPLESOTHER EXAMPLES

Au lieu d'un produit liant à base de silice colloidale, les barbotines de renfort utilisées peuvent comporter un produit liant à base de silicate d'éthyle. Une barbotine de renfort utilisable dans un tel mode de réalisation et conforme à l'invention peut comporter:

  • 35 % de silicate d'éthyle,
  • 23 % de farine de zircon,
  • 37 % de silice fondue,
  • 3 % de cristobalite,
  • 2 % d'un agent complémentaire de suspension.
Instead of a bonding product based on colloidal silica, the reinforcing slip used may include a bonding product based on ethyl silicate. A reinforcing slip usable in such a mode and according to the invention may include:
  • 35% ethyl silicate,
  • 23% zircon flour,
  • 37% fused silica,
  • 3% cristobalite,
  • 2% of an additional suspension agent.

Par ailleurs, les pourcentages de masse sèche peuvent varier dans les proportions entre silice fondue qui reste l'élément majoritaire et zircon. Notamment, dans un autre exemple de réalisation, la composition finale, en pourcentages de masse sèche, est de 95 % de silice fondue et 5 % de zircon. On notera par conséquent que ces pourcentages peuvent varier entre 70 et 95 % de silice fondue et entre 5 et 30 % de zircon.Furthermore, the percentages of dry mass can vary in the proportions between fused silica which remains the majority element and zircon. In particular, in another exemplary embodiment, the final composition, in percentages of dry mass, is 95% of fused silica and 5% of zircon. It should therefore be noted that these percentages can vary between 70 and 95% of fused silica and between 5 and 30% of zircon.

Les moules-carapaces conformes à l'invention dont les compositions viennent d'être décrites ci-dessus présentent l'avantage essentiel, en plus des propriétés habituelles requises par leur destination, de procurer des facilités intéressantes lors des opérations d'élimination, qui suivent nécessairement en fonderie l'étape de la coulée et solidification par refroidissement des pièces. En effet, ces compositions permettent d'appliquer un procédé remarquable d'élimination du moule-carapace qui comporte les étapes suivantes :

  • (a) élimination manuelle partielle du moule-carapace ;
  • (b) découpe des pièces coulées ;
  • (c) dissolution complète du moule-carapace en bain basique à base de soude ou de potasse.
The shell molds in accordance with the invention, the compositions of which have just been described above, have the essential advantage, in addition to the usual properties required by their destination, of providing advantageous facilities during the disposal operations which follow. necessarily in the foundry stage of casting and solidification by cooling of the parts. Indeed, these compositions make it possible to apply a remarkable process for eliminating the shell mold which comprises the following stages:
  • (a) partial manual elimination of the shell mold;
  • (b) cutting the castings;
  • (c) complete dissolution of the shell mold in a basic soda or potash bath.

Cette dernière étape (c) de dissolution qui caractérise l'invention peut notamment être mise en oeuvre en utilisant un autoclave et un bain de soude, dans des conditions moyennes de température et de pression de 200°C et de 1,5 MPa.This last step (c) of dissolution which characterizes the invention can in particular be implemented using an autoclave and a soda bath, under average conditions of temperature and pressure of 200 ° C. and 1.5 MPa.

Une solution alternative permet d'utiliser un bain de potasse à l'air.An alternative solution allows the use of an air potash bath.

On notera en outre que les compositions de moule-carapace conformes à l'invention grâce à la présence de silice fondue procure des avantages complémentaires et notamment :

  • - une amélioration des qualités mécaniques de la carapace à la coulée, due à une formation de cristobalite à hautes températures ;
  • - des propriétés de faible dilatation amenant une amélioration de la résistance aux chocs thermiques.
It will also be noted that the shell-mold compositions in accordance with the invention thanks to the presence of molten silica provides additional advantages and in particular:
  • - an improvement in the mechanical qualities of the shell during casting, due to the formation of cristobalite at high temperatures;
  • - low expansion properties resulting in improved resistance to thermal shock.

Claims (6)

1. Moule-carapace pour fonderie, notamment par un procédé à la cire perdue, caractérisé en ce qu'il est obtenu à partir de barbotines à base d'un produit liant du type silice colloïdale ou silicate d'éthyle et d'une charge minérale céramique à base de silice fondue et de zircon conduisant à une composition en pourcentages de masse sèche comprenant entre 70 et 95 % de silice fondue et entre 5 et 30 % de zircon.1. Shell mold for foundry, in particular by a lost-wax process, characterized in that it is obtained from slips based on a binder of the colloidal silica or ethyl silicate type and a filler ceramic mineral based on fused silica and zircon leading to a composition in dry mass percentages comprising between 70 and 95% fused silica and between 5 and 30% zircon. 2. Moule-carapace pour fonderie selon la revendication 1 obtenu par des opérations successives de trempé et séchage dans les barbotines suivantes : - (a) une première barbotine de contact comprenant : - 20 % de silice colloïdale, - 79 % de farine de zircon, - 1 % d'un agent complémentaire à propriétés mouillantes et anti-mouse ; - (b) une deuxième barbotine de contact comprenant : - 25 % de silice colloïdale, - 49 % de farine de zircon, - 25 % de farine de silice fondue, - 1 % d'un agent complémentaire à propriétés mouillantes et anti-mousse ; - (c) une barbotine de renfort, comprenant : - 20 % de silice colloïdale, - 33 % de farine de zircon, - 42 % de silice fondue, - 3 % de farine de cristobalite, - 2 % d'un agent complémentaire de suspension et comprenant au stade final, en pourcentages de masse sèche 70 % de silice fondue et 30 % de zircon. 2. Foundry shell mold according to claim 1 obtained by successive quenching and drying operations in the following slip: - (a) a first contact slip comprising: - 20% colloidal silica, - 79% zircon flour, - 1% of a complementary agent with wetting and anti-mouse properties; - (b) a second contact slip comprising: - 25% colloidal silica, - 49% zircon flour, - 25% of fused silica flour, - 1% of an additional agent with wetting and anti-foaming properties; - (c) a reinforcing slip, comprising: - 20% colloidal silica, - 33% zircon flour, - 42% of fused silica, - 3% cristobalite flour, - 2% of an additional suspension agent and comprising, at the final stage, in dry mass percentages 70% of fused silica and 30% of zircon. 3. Moule-carapace pour fonderie selon la revendication 1 obtenu par des opérations successives de trempé et séchage dans les barbotines suivantes : - (a) une première barbotine de contact comprenant : 20 % de silice colloïdale, 79 % de farine de zircon, 1 % d'un agent complémentaire à propriété mouillantes et anti-mousse, - (b) une deuxième barbotine de contact comprenant : 25 % de silice colloidale, 49 % de farine de zircon, 25 % de farine de silide fondue, 1 % d'un agent complémentaire à propriété mouillante et anti-mousse, - (c) une barbotine de renfort comprenant : 35 % de silicate d'éthyle, 23 % de farine de zircon, 37 % de silice fondue, 3 % de cristobalite, 2 % d'un agent complémentaire de suspension. 3. Foundry shell mold according to claim 1 obtained by successive quenching and drying operations in the following slip: - (a) a first contact slip comprising: 20% colloidal silica, 79% zircon flour, 1% of an additional agent with wetting and anti-foaming properties, - (b) a second contact slip comprising: 25% colloidal silica, 49% zircon flour, 25% melted silide flour, 1% of an additional wetting and anti-foaming agent, - (c) a reinforcing slip comprising: 35% ethyl silicate, 23% zircon flour, 37% fused silica, 3% cristobalite, 2% of an additional suspension agent. 4. Procédé d'élimination, après coulée des pièces, d'un moule-carapace conforme à l'une quelconque des revendications 1 à 3 caractérisé en ce qu'il comporte les étapes suivantes: - (a) élimination manuelle partielle du moule-carapace, - (b) découpe des pièces coulées, - (c) dissolution complète du moule-carapace en bain basique. 4. Method for removing, after casting the parts, a shell mold according to any one of claims 1 to 3, characterized in that it comprises the following steps: - (a) partial manual elimination of the shell mold, - (b) cutting of the castings, - (c) complete dissolution of the shell mold in basic bath. 5. Procédé d'élimination d'un moule-carapace selon la revendication 4 dans lequel l'étape (c) de dissolution est effectuée en autoclave dans un bain de soude, dans des conditions moyennes de température et de pression de 200°C et 1,5 MPa.5. Method for removing a shell mold according to claim 4, in which step (c) of dissolution is carried out in an autoclave in a sodium hydroxide bath, under average conditions of temperature and pressure of 200 ° C and 1.5 MPa. 6. Procédé d'élimination d'un moule-carapace selon la revendication 4 dans lequel l'étape (c) de dissolution d'un moule-carapace est effectuée dans un bain de potasse à l'air.6. Method for removing a shell mold according to claim 4, in which step (c) of dissolving a shell mold is carried out in an air potassium hydroxide bath.
EP91402625A 1990-10-03 1991-10-02 Soluble shell mould for foundry and method for disposal Expired - Lifetime EP0479672B1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
FR9012159A FR2667523B1 (en) 1990-10-03 1990-10-03 SOLUBLE SHELL MOLD FOR FOUNDRY AND DISPOSAL PROCESS.
FR9012159 1990-10-03

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Publication Number Publication Date
EP0479672A1 true EP0479672A1 (en) 1992-04-08
EP0479672B1 EP0479672B1 (en) 1995-08-02

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EP (1) EP0479672B1 (en)
JP (1) JPH04270025A (en)
DE (1) DE69111735T2 (en)
FR (1) FR2667523B1 (en)

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Publication number Priority date Publication date Assignee Title
WO2016157119A1 (en) * 2015-03-31 2016-10-06 Europea Microfusioni Aerospaziali S.P.A. Ceramic shell for lost-wax micro-casting
CN107138919A (en) * 2017-05-18 2017-09-08 西安建筑科技大学 The manufacture craft of the c-shaped opening cylindrical shell of runback bit function is unloaded with threshold value flexing
WO2018015701A1 (en) * 2016-07-22 2018-01-25 Safran Process for manufacturing a shell mold

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Publication number Priority date Publication date Assignee Title
CN104722703A (en) * 2015-04-03 2015-06-24 莱芜市泰钢新材料有限责任公司 Production method of precision casting surface layer sizing agent

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EP0251847A1 (en) * 1986-06-10 1988-01-07 Societe Nationale D'etude Et De Construction De Moteurs D'aviation "Snecma" Cristobalitic foundry shell mould, composition of the slurry and method of making the mould

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US3249972A (en) * 1964-01-31 1966-05-10 Prec Metalsmiths Inc Ceramic shell molds and methods of production
DE2351677B2 (en) * 1972-10-18 1976-07-01 Monsanto Ltd., London METHOD OF MANUFACTURING CERAMIC MOLDING MASKS FOR METAL CASTING
DE2321810B2 (en) * 1973-04-30 1976-05-20 Didier-Werke Ag, 6200 Wiesbaden FIRE-RESISTANT FIRED SHAPED BODIES AND METHOD OF MANUFACTURING THEREOF
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Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2016157119A1 (en) * 2015-03-31 2016-10-06 Europea Microfusioni Aerospaziali S.P.A. Ceramic shell for lost-wax micro-casting
WO2018015701A1 (en) * 2016-07-22 2018-01-25 Safran Process for manufacturing a shell mold
FR3054149A1 (en) * 2016-07-22 2018-01-26 Safran PROCESS FOR PRODUCING CARAPACE MOLD
US10987723B2 (en) 2016-07-22 2021-04-27 Safran Process for manufacturing a shell mold
CN107138919A (en) * 2017-05-18 2017-09-08 西安建筑科技大学 The manufacture craft of the c-shaped opening cylindrical shell of runback bit function is unloaded with threshold value flexing

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Publication number Publication date
EP0479672B1 (en) 1995-08-02
FR2667523B1 (en) 1993-07-09
FR2667523A1 (en) 1992-04-10
JPH04270025A (en) 1992-09-25
DE69111735T2 (en) 1996-02-01
DE69111735D1 (en) 1995-09-07

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