EP0968065B1 - Procede et appareil permettant de produire des moulages a solidification orientee - Google Patents

Procede et appareil permettant de produire des moulages a solidification orientee Download PDF

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Publication number
EP0968065B1
EP0968065B1 EP98946047A EP98946047A EP0968065B1 EP 0968065 B1 EP0968065 B1 EP 0968065B1 EP 98946047 A EP98946047 A EP 98946047A EP 98946047 A EP98946047 A EP 98946047A EP 0968065 B1 EP0968065 B1 EP 0968065B1
Authority
EP
European Patent Office
Prior art keywords
mold
water
tank
cooled
heating zone
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.)
Expired - Lifetime
Application number
EP98946047A
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German (de)
English (en)
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EP0968065A1 (fr
Inventor
Vegeny Nikolaevich Kablov
Viktor Vladimirovich Gerasimov
Joseph Markovich Demonis
Viatcheslav Alexeevitch Nikolaev
Elena Mikhailovna Visik
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.)
All Russian Scientific Research Institute of Aviation Materials
General Electric Co
Original Assignee
All Russian Scientific Research Institute of Aviation Materials
General Electric Co
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Publication of EP0968065A1 publication Critical patent/EP0968065A1/fr
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Classifications

    • 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
    • B22D27/04—Influencing the temperature of the metal, e.g. by heating or cooling the mould
    • B22D27/045—Directionally solidified castings

Definitions

  • the present invention relates to metal casting and can be used in producing castings with directional and single crystal structure.
  • the invention relates to a metal casting apparatus with a water-cooled tank having a truncated cone shape.
  • An apparatus for directional solidification generally comprises a vacuum chamber inside which there are disposed a mold heating zone, a baffle system, a water-cooled chill plate usually made of copper, an induction furnace, and a thermocouple system that automatically controlls and maintains the temperature in a cooling zone and in a heating zone within the furnace.
  • a vacuum chamber inside which there are disposed a mold heating zone, a baffle system, a water-cooled chill plate usually made of copper, an induction furnace, and a thermocouple system that automatically controlls and maintains the temperature in a cooling zone and in a heating zone within the furnace.
  • cooling zone is a liquid cooling bath with a material that melts easily to serve the role of the cooling medium.
  • the liquid metal bath is disclosed in U.S. Patent Nos 3763926 and 3915761, and Russian Federation Patent No 2010672.
  • the closest prior art to the present invention is an apparatus disclosed in French Patent Application 2604378, being accepted as a prototype.
  • This prototype apparatus comprises a vacuum chamber with a heating member inside where there is disposed a ceramic mold fixed on a water-cooled metallic plate which is moved up and down with the help of a rod and of an actuator for vertical transportation.
  • a horizontal baffle separates a heating zone and a cooling zone.
  • In the cooling zone concentrically with the chill plate, there is disposed an additional circular water-cooled cavity with the inner diameter exceeding the mold's maximal size.
  • Below the cavity there is disposed a container which is utilized for capturing the poured casting metal in the event of mold breakage.
  • the above apparatuses can function only when they comprise a crystallizer. It is impossible to use such installation for directional solidification processing with a liquid metal coolant and it is difficult to utilize the expensive alloys used in directional solidification castings in the event of mold breakage. Thus there is a need for a casting apparatus that provides a means that efficiently cools the molten cast alloy while protecting the equipment from damage in the event that the ceramic mold breaks while containing the molten cast alloy material.
  • the technical aim of this invention is to produce castings having the directional and single crystal structure by the method of radiation cooling without using the above-mentioned crystallizer.
  • Another aim of the invention is to be able to reconstruct easily the invented apparatus for both radiation crystallization processing and liquid metal cooling crystallization processing.
  • the inventive apparatus also increases the reliability and economic profit due to the apparatus' performance.
  • the invention comprises an apparatus in accordance with claim 1 hereof and a method in accordance with claim 9.
  • the inventive apparatus comprises a vacuum chamber inside which there is disposed an induction melting furnace, a mold preheating furnace with a ceramic mold, a drive assembly for mold transportation and a water-cooled tank.
  • the drive assembly comprises a rod on which the mold is fixed with the help of a hanger and a regulating actuator for vertical movement being positioned above the vacuum chamber.
  • the water-cooled tank is shaped as a truncated cone. Its upper portion is opened towards the heating zone, and its bottom portion has a smaller base than the upper portion.
  • a baffle separates the heating zone inside the induction furnace from the cooling zone; said baffle moves in a horizontal plane and closely adjoins the mold during the solidification process. It consists of the segments or sectors (not less than 2 from each side).
  • the apparatus performs as follows: the mold (1) is disposed on the hanger (2) and is fixed on the movable rod (3).
  • the hanger (2), the movable rod (3), and the regulating actuator comprise the drive assembly (14).
  • the mold (1) is placed into the mold preheater furnace (9) with the help of the actuator while regulating the mold position relative to the heater (4).
  • the heat baffle (5) is disposed under the heating zone (10).
  • the top butt end of the water-cooled tank (6) adjoins the baffle's (5) lower surface and is positioned coaxially with the heater (4) and (11).
  • the vacuum chamber (12) is evacuated to 1 x 10 -3 mm m.c.
  • the mold preheating furnace (9) is switched on.
  • the induction furnace's heater (11) Upon reaching the mold temperature of 100-150 °C higher than the liquidus temperature of the alloy being cast, the induction furnace's heater (11) is switched on, the alloy (7) being cast melts and is poured into the heated ceramic mold at the predetermined temperature. After that, the actuator for vertical transportation lowers the mold from the heating zone (10) into the cooling zone (13) at the required rate. Solidification of the molten cast alloy occurs by radiation onto the cold walls of the water-cooled tank. Due to this fact it becomes possible to produce large sized castings with directional and single crystal microstructure. Large size castings can include blades, nozzles, buckets, airfoils, and the like, that are used both in aircraft and land-based turbine engines. The castings are often greater than 30 inches in overall height.
  • the heater (4 and 11) is switched off.
  • the temperature is decreased to 300-400 °C, the mold with the solidified casting alloy is extracted from the installation which has been previously decompressed. Then the process is repeated for the next mold.
  • a single crystal seed with proper orientation is positioned into the top of the starting zone (8) of the ceramic mold before it is disposed in the vacuum chamber. Then the mold position is strictly fixed relative to the heater. In such event the seed and the solidified portion of the starting zone serve as a cooling medium, and further solidification of the melt is caused by radiation cooling in the water-cooled tank as stated above.
  • the use of the water-cooled tank instead of a chill plate allows the same or better working efficiency of said tank than that of a chill plate or of the prototype circular water-cooled cavity. At the same time the water-cooled tank of this invention does not require the use of a complex drive assembly with airtight seals.
  • the heat baffle (5) is used for raising the axial temperature gradient at the solidification front.
  • Said baffle moves in a horizontal plane, closely adjoins the ceramic mold according to its geometry during the solidification process and consists of the segments or sectors (not less than 2 from each side).
  • the water-cooled tank may be made of stainless steel and contain a double layer wall surrounding the perimeter of the tank. A vacuum atmosphere is created in the tank to further aid in the cooling of the cast parts.
  • the tank may also effectively function as a mold catch basin in the event of mold breakage, and the expensive, poured casting alloy may be easily removed from the tapered tank and be remelted.
  • the apparatus of this invention allows one to produce high quality castings having the directional and single crystal structure, including the large sized castings used in the land based turbine industry, by the method of radiation cooling without using the crystallizers of the prior art.
  • the invention also gives the possibility to reconstruct easily the disclosed apparatus for liquid metal cooling crystallization processing, to use successively the invented water-cooled tank as a mold catch basin in the event of mold breakage, and to increase the reliability and economic profitability of the apparatus' performance.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Crystals, And After-Treatments Of Crystals (AREA)
  • Moulding By Coating Moulds (AREA)

Claims (10)

  1. Appareil servant à produire des pièces moulées à structure directionnelle et monocristalline, l'appareil comprenant une chambre à vide (12) dans laquelle est positionné un four de fusion à induction (15), et un four de préchauffage (9) de moule, un moule en céramique (1) étant fixé à un ensemble d'entraínement de transport (14) comprenant une tige (3) et un actionneur (14) pour le mouvement vertical, un moyen de refroidissement, un écran (5) séparant une zone de chauffage (10) et un réservoir (6) refroidi par eau ayant une partie inférieure fermée (16) et une partie supérieure (17) ouverte vers la zone de chauffage (10), caractérisé en ce que le moyen de refroidissement est constitué par ledit réservoir (6) refroidi par eau et l'actionneur est positionné au-dessus de la chambre à vide.
  2. Appareil selon la revendication 1, caractérisé en ce que le réservoir (6) refroidi par eau a une forme de cône tronqué, dont la partie inférieure (16) a une base plus petite que la partie supérieure (17) du réservoir (6).
  3. Appareil selon la revendication 1, caractérisé en ce qu'un écran (5) est articulé dans un plan horizontal et est constitué d'au moins deux secteurs ou segments, qui sont étroitement contigus au moule en céramique (1) pendant un processus de solidification.
  4. Appareil selon la revendication 1, dans lequel l'ensemble d'entraínement (14) comprend en outre un dispositif de suspension (2) de moule.
  5. Appareil selon la revendication 1, dans lequel ledit réservoir (6) refroidi par eau peut être utilisé comme bassin épurateur de moule.
  6. Appareil selon la revendication 1, dans lequel ledit moule (1) contient une cavité de démarrage (8) pour un cristal ayant une orientation cristalline définie.
  7. Appareil selon la revendication 1, dans lequel le réservoir (6) refroidi par eau a une double paroi.
  8. Appareil selon la revendication 1, dans lequel le réservoir (6) refroidi par eau est en acier inoxydable.
  9. Procédé de fabrication d'une structure d'alliage directionnel ou monocristallin, comprenant les étapes consistant à : placer un moule (1) dans un four de préchauffage (9) de moule par rapport à un dispositif de chauffage (4), le moule étant fixé à un ensemble d'entraínement de transport comprenant une tige (3) et un actionneur (14) pour le mouvement vertical positionné au-dessus de la chambre à vide, faire chauffer le moule (1) à une température d'environ 100 à 150 °C au-dessus de la température de liquidus d'un alliage de moulage, faire fondre l'alliage de moulage, verser l'alliage fondu (7) dans le moule chauffé (1), abaisser le moule (1) avec l'alliage fondu à une vitesse requise d'une zone de chauffage (10) à une zone de refroidissement (13) constituée d'un réservoir (6) refroidi par eau comprenant une partie inférieure fermée et une partie supérieure ouverte avec des parois refroidies par eau s'étendant entre elles, et faire solidifier l'alliage fondu en le répandant sur les parois refroidies par eau du réservoir (6).
  10. Procédé selon la revendication 9, dans lequel le moule (1) passe à travers un écran (5) situé entre la zone de chauffage (10) et la zone de refroidissement (13).
EP98946047A 1997-09-12 1998-09-14 Procede et appareil permettant de produire des moulages a solidification orientee Expired - Lifetime EP0968065B1 (fr)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
RU97115515A RU2117550C1 (ru) 1997-09-12 1997-09-12 Устройство для получения отливок с направленной и монокристаллической структурой
RU97115515 1997-09-12
PCT/US1998/019021 WO1999012679A1 (fr) 1997-09-12 1998-09-14 Procede et appareil permettant de produire des moulages a solidification orientee

Publications (2)

Publication Number Publication Date
EP0968065A1 EP0968065A1 (fr) 2000-01-05
EP0968065B1 true EP0968065B1 (fr) 2004-12-01

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EP98946047A Expired - Lifetime EP0968065B1 (fr) 1997-09-12 1998-09-14 Procede et appareil permettant de produire des moulages a solidification orientee

Country Status (5)

Country Link
EP (1) EP0968065B1 (fr)
AT (1) ATE283746T1 (fr)
DE (1) DE69827932D1 (fr)
RU (1) RU2117550C1 (fr)
WO (1) WO1999012679A1 (fr)

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN103394674A (zh) * 2013-07-24 2013-11-20 西安工程大学 薄壁铸件铸造用真空感应炉及铸造薄壁钛合金铸件的方法
US8752611B2 (en) 2011-08-04 2014-06-17 General Electric Company System and method for directional casting
CN106180589A (zh) * 2016-07-19 2016-12-07 柳州三木科技有限公司 一种播种机轮毂的锻造方法

Families Citing this family (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1162016B1 (fr) * 2000-05-13 2004-07-21 ALSTOM Technology Ltd Appareil pour la coulée d'une pièce solidifiée directionellement
KR100416303B1 (ko) * 2000-12-28 2004-01-31 이재현 일방향응고용 시편제조장치
US6896030B2 (en) 2003-07-30 2005-05-24 Howmet Corporation Directional solidification method and apparatus
CN102278881A (zh) * 2011-08-12 2011-12-14 上海理工大学 快速凝固的真空感应熔炼炉
CN112157245B (zh) * 2020-09-03 2022-03-29 中国科学院金属研究所 利用lmc定向凝固技术制备大尺寸定向叶片过程中定向柱晶晶粒控制方法
RU2754215C1 (ru) * 2020-11-02 2021-08-30 Федеральное государственное унитарное предприятие "Всероссийский научно-исследовательский институт авиационных материалов" (ФГУП "ВИАМ") Устройство для получения крупногабаритных отливок с направленной и монокристаллической структурой
RU2754333C1 (ru) * 2021-03-02 2021-09-01 Акционерное общество «ОДК-Авиадвигатель» Способ изготовления керамических оболочковых форм для литья по выплавляемым моделям лопаток турбин с направленной и монокристаллической структурой
CN114734024A (zh) * 2022-03-31 2022-07-12 上海元定科技有限公司 一种液体金属冷却真空精密铸造炉及工作方法
CN114505467B (zh) * 2022-04-06 2022-07-01 太原科技大学 一种利用电磁感应补温的铝合金铸造模具及铸造方法

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US3532155A (en) * 1967-12-05 1970-10-06 Martin Metals Co Process for producing directionally solidified castings
US3680625A (en) * 1970-11-12 1972-08-01 Trw Inc Heat reflector
US3763926A (en) * 1971-09-15 1973-10-09 United Aircraft Corp Apparatus for casting of directionally solidified articles
US3915761A (en) * 1971-09-15 1975-10-28 United Technologies Corp Unidirectionally solidified alloy articles
FR2604378B1 (fr) * 1978-06-30 1989-10-27 Snecma Appareillage de fonderie pour la fabrication de pieces metalliques moulees a structure orientee
US4804311A (en) * 1981-12-14 1989-02-14 United Technologies Corporation Transverse directional solidification of metal single crystal articles
US4412577A (en) * 1982-01-27 1983-11-01 United Technologies Corporation Control of seed melt-back during directional solidification of metals
US5197531A (en) * 1990-06-13 1993-03-30 Leybold Aktiengesellschaft Method of manufacturing directionally solidified castings
RU2010672C1 (ru) * 1991-02-15 1994-04-15 Всероссийский научно-исследовательский институт авиационных материалов Способ получения монокристаллических отливок
EP0631832B1 (fr) * 1993-07-02 1998-05-20 ALD Vacuum Technologies GmbH Procédé et dispositif pour la coulée par solidification dirigée de métal en fusion
DE19539770A1 (de) * 1995-06-20 1997-01-02 Abb Research Ltd Verfahren zur Herstellung eines gerichtet erstarrten Gießkörpers und Vorrichtung zur Durchführung dieses Verfahrens
DE19602554C1 (de) * 1996-01-25 1997-09-18 Ald Vacuum Techn Gmbh Verfahren und Vorrichtung zum gleichzeitigen Gießen und gerichteten Erstarren von mehreren Gußkörpern

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US8752611B2 (en) 2011-08-04 2014-06-17 General Electric Company System and method for directional casting
US9597728B2 (en) 2011-08-04 2017-03-21 General Electric Company System and article of manufacture for directional casting
CN103394674A (zh) * 2013-07-24 2013-11-20 西安工程大学 薄壁铸件铸造用真空感应炉及铸造薄壁钛合金铸件的方法
CN103394674B (zh) * 2013-07-24 2016-01-13 西安工程大学 薄壁铸件铸造用真空感应炉及铸造薄壁钛合金铸件的方法
CN106180589A (zh) * 2016-07-19 2016-12-07 柳州三木科技有限公司 一种播种机轮毂的锻造方法

Also Published As

Publication number Publication date
EP0968065A1 (fr) 2000-01-05
ATE283746T1 (de) 2004-12-15
RU2117550C1 (ru) 1998-08-20
WO1999012679A1 (fr) 1999-03-18
DE69827932D1 (de) 2005-01-05

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