EP1013781B1 - Method for making die cast nickel-based superalloy articles - Google Patents

Method for making die cast nickel-based superalloy articles Download PDF

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Publication number
EP1013781B1
EP1013781B1 EP99310535A EP99310535A EP1013781B1 EP 1013781 B1 EP1013781 B1 EP 1013781B1 EP 99310535 A EP99310535 A EP 99310535A EP 99310535 A EP99310535 A EP 99310535A EP 1013781 B1 EP1013781 B1 EP 1013781B1
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EP
European Patent Office
Prior art keywords
die
articles
cast
ksi
temperature
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EP99310535A
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German (de)
English (en)
French (fr)
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EP1013781A2 (en
EP1013781A3 (en
Inventor
John Joseph Schirra
Ralph Giugno
Walter Frederick Gustafson
John Joseph Marcin Jr.
Jeffrey William Samuelson
Delwyn Earle Norton
Jay John Nunes
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Raytheon Technologies Corp
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United Technologies Corp
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    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C19/00—Alloys based on nickel or cobalt
    • C22C19/03—Alloys based on nickel or cobalt based on nickel
    • C22C19/05—Alloys based on nickel or cobalt based on nickel with chromium
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
    • C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
    • C22F1/10—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of nickel or cobalt or alloys based thereon
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C1/00—Making non-ferrous alloys
    • C22C1/02—Making non-ferrous alloys by melting
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C19/00—Alloys based on nickel or cobalt
    • C22C19/03—Alloys based on nickel or cobalt based on nickel
    • C22C19/05—Alloys based on nickel or cobalt based on nickel with chromium
    • C22C19/051—Alloys based on nickel or cobalt based on nickel with chromium and Mo or W
    • C22C19/055—Alloys based on nickel or cobalt based on nickel with chromium and Mo or W with the maximum Cr content being at least 20% but less than 30%
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C19/00—Alloys based on nickel or cobalt
    • C22C19/03—Alloys based on nickel or cobalt based on nickel
    • C22C19/05—Alloys based on nickel or cobalt based on nickel with chromium
    • C22C19/051—Alloys based on nickel or cobalt based on nickel with chromium and Mo or W
    • C22C19/056—Alloys based on nickel or cobalt based on nickel with chromium and Mo or W with the maximum Cr content being at least 10% but less than 20%
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C19/00—Alloys based on nickel or cobalt
    • C22C19/07—Alloys based on nickel or cobalt based on cobalt
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
    • F01D5/12—Blades
    • F01D5/28—Selecting particular materials; Particular measures relating thereto; Measures against erosion or corrosion
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05C—INDEXING SCHEME RELATING TO MATERIALS, MATERIAL PROPERTIES OR MATERIAL CHARACTERISTICS FOR MACHINES, ENGINES OR PUMPS OTHER THAN NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES
    • F05C2201/00—Metals
    • F05C2201/04—Heavy metals
    • F05C2201/0433—Iron group; Ferrous alloys, e.g. steel
    • F05C2201/0466—Nickel

Definitions

  • the present invention relates generally to articles fabricated from superalloy material, and relates more particularly to articles fabricated from nickel base superalloys and to methods of heat treating such alloys.
  • Such alloys typically have high melting temperatures, in excess of 1260 - 1371 °C/2300 - 2500 °F.
  • Nickel base superalloys are employed in applications which require high strength-weight ratios, corrosion resistance and use up to relatively high temperatures, e.g., up to and above about 1093 °C/2000 °F.
  • these superalloys are typically employed in the turbine section, and sometimes in the latter stages of the compressor section of the engine, including but not limited to airfoils such as blades and vanes, as well as static and structural components such as intermediate and compressor cases, compressor disks, turbine cases and turbine disks.
  • a typical nickel base superalloy utilized in gas turbine engines is Inconel 718 (IN 718), in broad terms having a composition in weight percent, of about 0.01 - 0.05 Carbon (C), 13 - 25 Chromium (Cr), 2.5 - 3.5 Molybdenum (Mo), 5.0 - 5.75 (Niobium (Nb)] + Tantalum (Ta)), 0.7 - 1.2 Titanium (Ti), 0.3 - 0.9 Aluminum (Al), up to about 21 Iron (Fe), balance generally Ni.
  • Nickel base superalloys have traditionally been precision forged to produce parts having a fine average grain size and a balance of high strength, low weight, and good high cycle fatigue resistance. When properly produced, these parts do exhibit a balance of high strength, low weight, and durability.
  • an ingot of material is first obtained having a composition corresponding to the desired composition of the finished component.
  • the ingot is converted into billet form, typically cylindrical for blades and vanes, and is then thermomechanically processed, such as by heating and stamping several times between dies and/or hammers which may be heated and are shaped progressively similar to the desired shape, in order to plastically deform and flow the material into the desired component shape.
  • Each component is typically heat treated to obtain desired properties, e.g., hardening/strengthening, stress relief, resistance to crack nucleation and a particular level of HCF resistance, and is also finished, e.g., machined, chem-milled and/or media finished, as needed to provide the component with the precise shape, dimensions or features.
  • desired properties e.g., hardening/strengthening, stress relief, resistance to crack nucleation and a particular level of HCF resistance
  • finished e.g., machined, chem-milled and/or media finished, as needed to provide the component with the precise shape, dimensions or features.
  • Forging typically includes a series of operations, each requiring separate dies and associated equipment.
  • the post-forging finishing operations e.g., machining the root portion of a blade and providing the appropriate surface finish, comprise a significant portion of the overall cost of producing forged parts, and include a significant portion of parts which must be scrapped.
  • Nickel base superalloys such as IN 718 also exhibit significant springback, e.g., the material is resilient, and the springback must be taken into account during forging, i.e., the parts must typically be "over forged". As noted above, finished components may still require extensive post forging processing.
  • Forged components also often exhibit significant levels of defects, including inclusions and carbides, which vary significantly from component to component.
  • Components having higher columbium contents e.g., IN 718
  • the presence and degree of these defects detrimentally affects the mechanical properties, particularly at elevated temperatures.
  • the extent of these defects typically depends upon the material composition, and the length of time the component is exposed to elevated temperature, e.g., during forging.
  • the articles are heat treated to reduce or remove the defects, e.g., homogenization heat treatment, which occurs as a separate step in addition to any other treatment steps performed on the articles.
  • the heat treatment typically includes exposing the article to a relatively high temperature, e.g., around 1093 °C/2000 °F for a period of up to several hours.
  • the temperature is high enough to reduce segregation, but not so high or for so long as to enable significant grain growth to occur.
  • Casting has been extensively used to produce relatively near-finished-shape articles.
  • Investment casting in which molten metal is poured into a ceramic shell having a cavity in the shape of the article to be cast, can be used to produce such articles.
  • investment casting produces articles having extremely large grains (relative to the small average grain size achievable by forging), and in some cases the entire part comprises a single grain.
  • solidification rates may result in the presence of unacceptable amounts of elemental segregation producing large scatter (variances from part to part) in test results or in the presence of brittle phases also resulting in reduced properties.
  • this process is expensive. Reproducibility of very precise dimensions from part to part is difficult to achieve.
  • molten material is melted, poured and/or solidified in air or other gas, results in parts having undesirable properties such as inclusions and porosity, particularly for materials containing reactive elements.
  • the porosity must be eliminated, e.g., by heating the article and subjecting the article to pressure.
  • the articles are typically HIP'd at a temperature of between 982 - 1024 °C/1800 - 1875 °F, at a pressure of between 105 - 154 MPa/15 - 22 ksi for several hours. Spallation of the ceramic shell also contributes to the presence of inclusions and impurities in the cast articles.
  • Permanent mold casting in which molten material is poured into a multipart, reusable mold and flows into the mold under only the force of gravity, has also been used to cast parts generally. See. e.g., U.S. Pat. No. 5,505,246 to Colvin.
  • permanent mold casting has several drawbacks. For thin castings, such as airfoils, the force of gravity may be insufficient to urge the material into thinner sections, particularly so where high melting temperature materials and low superheats are employed, and accordingly the mold does not consistently fill and the parts must be scrapped. Dimensional tolerances must be relatively large, and require correspondingly more post casting work, and repeatably is difficult to achieve. Permanent mold casting also results in relatively poor surface finish, which also requires more post cast work.
  • U.S. Pat. No. 3,791,440 One type of die casting machine is set forth in U.S. Pat. No. 3,791,440.
  • the machine includes a fixed die element 11 and a moveable die element 12.
  • molten metal is poured through a pour spout 22 and sprue 21, and flows into an injection cylinder 30 which communicates with the die cavity 15.
  • Sufficient molten material is poured to fill the injection cylinder 30 and a portion of the sprue 21, thus displacing air from the injection cylinder. See. e.g., col. 6, lines 7-17.
  • An injection plunger 38 forces material from the injection cylinder 30 into the die cavity 15.
  • a sprue locking cylinder and associated plunger 35 can seal the sprue 21. e.g., during injection.
  • the injection cylinder 30 is embedded in one of the die platens, thereby preventing distortion of the cylinder when high melting temperature, molten material is poured into the injection cylinder.
  • the Cross-type machine does not utilize a vacuum environment, but rather utilizes complete filling of the cylinder to prevent injecting air into the die.
  • Such machines are expensive. Moreover, this type of machine is not readily available, and is correspondingly expensive to refurbish and repair, as needed. For example, it would be difficult and expensive at best to attach a vacuum system to the machine, since the sleeve is embedded in a platen and not readily accessible. Moreover, it would be difficult at best to transfer molten material from a melting unit to the pour spout 22, within a vacuum environment. Controlling the temperature of the die would also be difficult, not only due to the physical size of the platen/embedded die combination, but also due to the thermal mass of such a combination. The configuration of the machine would also render release of the part difficult within a vacuum environment.
  • a conventional, cold chamber die casting machine includes a shot sleeve mounted to one (typically fixed) platen of a multiple part die, e.g., a two part dic including fixed and movable platens which cooperate to define a die cavity.
  • the shot sleeve can be oriented horizontally, vertically or inclined between horizontal and vertical.
  • the sleeve communicates with a runner of the die, and includes an opening on top of the sleeve through which molten metal is poured.
  • a plunger is positioned for movement in the sleeve, and forces molten metal that is present in the sleeve into the die.
  • the shot sleeve In a "cold type" machine, the shot sleeve is oriented horizontally and is unheated. Casting typically occurs under atmospheric conditions, i.e., the equipment is not located in a non-reactive environment such as a vacuum chamber.
  • the plunger since the shot sleeve is unheated, a skin or "can" of molten metal solidifies on the inside of the shot sleeve, and in order to move the plunger through the sleeve to inject the molten metal into the die, the plunger must scrape the skin off of the sleeve and "crush the can".
  • the can forms a structurally strong member, e.g., in the form of cylinder which is supported by the sleeve, the plunger and/or associated structure for moving the plunger can be damaged or destroyed.
  • the plunger can allow the passage of metal between plunger and sleeve ("blowback") and/or any entrapped gas between the plunger and sleeve, all of which detrimentally affects the quality of the resulting articles. See also U.S. Pat. No. 3,533,464 to Parlanti et al.
  • a method of manufacturing a gas turbine engine component having substantially no porosity, elemental segregation between 0-40% and an average grain size of ASTM 3 or smaller comprising the steps of : providing nickel based superalloy material having a composition in weight percent of 0.02-0.04 C, 17-21 Cr, 2.8-3.3 Mo + W + Re, 5.15-5.5 Nb + Ta, 0.75-1.15 Ti + V + Hf, 0.4-0.7 Al, up to 19 Fe, optionally up to 0.35 Mn, up to 0.15 Si, up to 1 Co, the balance being Ni and incidental impurities; melting the superalloy material and superheating it to a temperature of less than 93°C/200°F over the melting point; die casting the superalloy material into a shape of a gas turbine engine component; heating the as cast article to a temperature of 982-1023°C/1800-1875°F for at least four hours whilst subjecting the article to a pressure of between 105-175 Mp
  • the articles preferably at least meet the strength, low crack growth rates and stress rupture resistance requirements of corresponding forged articles, e.g., according to AMS 5663 or AMS 53 83.
  • the articles for example include a blade or vane for a gas turbine engine.
  • Each article has a microstructure similar to that of forged material, and is characterized by a more uniform grains, and a fine average grain size for a cast article, e.g., smaller than about ASTM 3, more preferably ASTM 5 or smaller.
  • the microstructure preferably is further characterized by an absence of flowlines.
  • the preferred average grain size is smaller, e.g., preferably ASTM 5 or smaller, more preferably ASTM 6 or smaller.
  • An advantage of the present invention is that die casting significantly reduces the time required to produce a part, from ingot to finished part, as there is no need to prepare specially tailored billets of material or ceramic investment shell, and casting broadly is performed in a single step, as opposed to multiple forging operations or shell preparations.
  • die casting enables the production of multiple parts in a single casting.
  • Die casting further enables production of parts having more complex three dimensional shapes, thereby enabling production of more aerodynamically efficient airfoils, and other components relative to forging.
  • the present invention will enable the production of articles utilizing materials having shapes that are difficult or impossible to forge into those shapes.
  • die cast parts have greater reproducibility than forged or investment cast articles, and can be produced nearer to their finished shape, and with a superior surface finish, which minimizes post forming finishing operations, all of which also reduces the cost of producing such parts. Additional advantages will become apparent in view of the following drawings and detailed description.
  • the article includes a blade 10 composed of IN 718 and which is used in a gas turbine engine.
  • the article includes an airfoil 12, a platform 14, and a root 16.
  • the present invention is broadly applicable to various applications, and is not intended to be limited to any particular article or to use in gas turbine engines.
  • the die cast components for use in a gas turbine engine exhibit strengths, low crack growth rates and high stress rupture resistance set forth in Aerospace Material Specification AMS 5663 (Rev. J, publ. Sep. 1997) (for corresponding forged components) or AMS 5383 (Rev. D, publ. Apr. 1993) (for corresponding investment cast components - for lower strength applications relative to AMS 5663) published by SAE Int'l of Warrendale, PA.
  • Inconel 718 As noted above, a typical nickel base superalloy utilized in gas turbine engines is Inconel 718 (IN 718), which nominally includes in weight percent about 19 Cr, 3.1 Mo, about 5.3 (Nb + Ta), 0.9 Ti, 0.6 Al, 19 Fe, balance.
  • IN 718 includes in weight percent, about 0.01 - 0.05 Carbon (C), up to about 0.4 Manganese (Mn), up to about 0.2 Silicon (Si), 13 - 25 Chromium (Cr), up to about 1.5 Cobalt (Co), 2.5 - 3.5 Molybdenum (Mo), 5.0 - 5.75 (Niobium (Nb) + Tantalum (Ta), 0.7 1.2 Titanium (Ti), 0.3 - 0.9 Aluminum (Al), up to about 21 Iron (Fe), balance essentially Ni.
  • the superalloy material has a composition of about 0.02 - 0.04 C, up to about 0.35 Mn, up to about 0.15 Si, 17 - 21 Cr, up to about 1 Co, 2.8 - 3.3 Mo + W + Re, 5.15 - 5.5 Nb + Ta, 0.75 - 1.15 Ti + V + Hf, 0.4 -0.7 Al, up to about 19 Fe, balance essentially Ni and traces of other elements.
  • compositional modifications can be made to IN 718, e.g., increasing the Nb content of the material to be cast, as well as other strengthening elements to improve strength and capability.
  • the alloy is heated and melted in a non-reactive, e.g., an inert or preferably in a vacuum environment, preferably maintained at a pressure of less than 100 ⁇ m more preferably at less than 50 ⁇ m.
  • the alloy is also heated to a controlled, limited superheat, within 38 - 93°C/100°F to 200°F above the melting temperature of the alloy and more preferably within 10- 38°C/50°F to 100°F, and preferably using a non-contaminating melting device.
  • a ceramic free melting system such as an inducto-skull melting unit.
  • the material is sufficiently superheated to ensure that it remains molten until injected into the die, but not enough to prevent rapid solidification of the molten material after injection.
  • Molten alloy is then transferred to a horizontal shot sleeve of the machine, which is preferably located in a vacuum environment and the molten material is injected under pressure into a reusable mold.
  • the process comprising pouring and injecting the molten material should not exceed a few seconds, with injection occurring preferably in less than one or two seconds, in a die casting machine having an unheated shot sleeve.
  • the articles may be thermomechanically processed after casting, if desired.
  • the articles may be forged after being die cast; e.g., the die cast articles may serve as pre-forms for use in a forging operation.
  • the die cast articles be cast to near net shape, so as to minimize post-casting work and associated expense performed on the articles.
  • articles prepared in accordance with the preferred embodiments are characterized by a microstructure having a fine, uniform average grain size, particularly for cast articles, and an absence of flow lines.
  • FIGS. 2 and 3 illustrating the microstructure of a die cast IN 718 test bar and an airfoil, respectively, and FIG. 5 illustrating the microstructure of a conventional, forged IN 718 airfoil.
  • the average grain size is roughly ASTM 6.
  • the average grain size is roughly ASTM 10.
  • the articles are characterized by a small average grain size, e.g., for non-rotating gas turbine engine components such as cases and seals, the average grain size is ASTM 3 or smaller, more preferably ASTM 5 or smaller.
  • the preferred average grain size is smaller, e.g., preferably ASTM 5 of smaller, more preferably ASTM 6 or smaller.
  • the preferred average grain size and maximum allowable grain size will depend upon the application of the part, e.g., whether the article is intended for use in a gas turbine engine versus other application, rotating vs. non-rotating parts, operating in lower temperature versus higher temperature environments.
  • Such articles have properties comparable to, and preferably at least equivalent to, corresponding articles composed of forged material.
  • the present invention enables the die casting of articles that have not only good strength, but also have other properties that are comparable to or better than corresponding forged components, e.g., low crack growth rates and high stress rupture resistance.
  • Samples of die cast IN 718 in accordance with preferred embodiments of the present invention were tested to determine yield and ultimate tensile strengths, as well as ductility and impact strength. With respect to tensile properties, samples of die cast IN 718 articles were tested both at room temperature (about 20 °C/ 70 °F) and elevated temperatures, e.g., about 650 °C/1200 °F held for a period of time prior to testing.
  • the die cast articles are characterized, at room temperature and at elevated temperatures, by comparable 0.2% yield strengths, ultimate tensile strengths, elongation at failure and impact strengths.
  • Blades, vanes and rotating components e.g., rotating components
  • die cast parts require at least strength and impact properties equivalent to those exhibited by corresponding forged articles.
  • Blades, vanes and rotating components composed of IN 718 should have a 0.2% yield strength at room temperature of at least 1 GPa/140 ksi and more preferably at least 1.05 GPa/150 ksi and most preferably at least 1.12 GPa/160 ksi; and at yield strength at 650 °C/1200 °F of at least 805 MPa/115 ksi and more preferably 875 MPa/125 ksi and most preferably at least 945 MPa/135 ksi.
  • Such articles have a ultimate tensile strength at room temperature of at least 1.23 GPa/175 ksi and more preferably at least 1.3GPa/185 ksi and most preferably at least 1.37 GPa/195 ksi; and an ultimate tensile strength at 650 °C/1200 °F of at least 1 GPa/a140 ksi and more preferably 1.05 GPa/150 ksi and most preferably at least 1.12GPa/160 ksi.
  • test specimens comprising material produced in accordance with a preferred embodiment of the present invention
  • ASTM E292 standard combination smooth and notched stress rupture test specimens
  • the specimens were maintained at about 650°C/1200°F and loaded continuously, after generating an initial axial stress of between about 735 - 770 MPa/105 - 110 ksi.
  • the specimens ruptured only after at least 23 hours. The values are comparable to those found in AMS 5663, referenced above.
  • Similar standard combination smooth and notched stress rupture test specimens (comprising material produced in accordance with a preferred embodiment of the present invention), e.g., conforming to ASTM E292, were also tested at about 704 °C/1300 °F.
  • the specimens were loaded continuously, after generating an initial axial stress of between about 420 - 455 MPa/60 - 65 ksi. In the case of material to be used for blades and vanes, the specimens ruptured only after at least 40 hours.
  • Creep properties were also evaluated, at about 650 °C/1200 °F.
  • the specimens were maintained at about 650° C/1200° F, and loaded to produce an axial stress of at least about 560 MPa/80 ksi.
  • the time to 0.1% plastic deformation was measured, in the case ofmaterial to be used for blades and vanes, should exceed about 15 hours. Again, the specific required values will differ depending upon the particular use to which the articles are being put.
  • non-rotating parts such as cases, flanges and seals, e.g., rings the above values are in excess of the values required. More specifically, for non-rotating parts such as rings and seals composed of IN 718 should have a 0.2% yield strength at room temperature of at least 910 MPa/130 ksi and more preferably at least 1 GPa/140 ksi and most preferably at least 1.05 GPa/150 ksi; and a yield strength at 650 °C/1200 °F of at least 735 MPa/105 ksi and more preferably 805 MPa/115 ksi and most preferably at least 875 MPa/125 ksi.
  • Such articles have a ultimate tensile strength at room temperature of at least 1.16 GPa/165 ksi and more preferably at least 1.23 GPa/175 ksi and most preferably at least 1.3 GPa/185 ksi; and an ultimate tensile strength at 650°C/1200°F of at least 875 MPa/125 ksi and more preferably 945 MPa/135 ksi and most preferably at least 1.02 GPa/145 ksi.
  • test specimens comprising material produced in accordance with a preferred embodiment of the present invention
  • ASTM E292 standard combination smooth and notched stress rupture test specimens
  • the specimens were maintained at about 650 °C/1200 °F and loaded continuously, after generating an initial axial stress of between about 735 - 770 MPa/105 - 110 ksi.
  • the specimens ruptured only after at least 23 hours, and the elongation was at least about 6 %.
  • Similar standard combination smooth and notched stress rupture test specimens (comprising material produced in accordance with a preferred embodiment of the present invention), e.g., conforming to ASTM E292, were also tested at about 704 °C/1300 °F.
  • the specimens were loaded continuously, after generating an initial axial stress of between about 420 - 455 MPa/60 - 65 ksi. In the case of material to be used for blades and vanes, the specimens ruptured only after at least 85 hours.
  • Creep properties were also evaluated, at about 650 °C/1200 °F.
  • the specimens were maintained at about 650°C/1200°F, and loaded to produce an axial stress of at least about 560MPa/80 ksi.
  • the time to 0.1% plastic deformation was measured, in the case of material to be used for blades and vanes, should exceed about 15 hours. Again, the specific required values will differ depending upon the particular use to which the articles are being put.
  • AMS 5663 calls for the following properties: Property Room Temp. 1200 °F +/- 10 (650 °C) Tensile Strength, min. 1.26GPa/180 ksi 1GPa/140 ksi Yield Strength, 0.2% offset, min. 1.05GPa/150 ksi 875MPa/125 ksi Elongation in 4D, min. 10% 10% Reduction in area, min. 12% 12%
  • AMS 5383 calls for the following properties: Property Room Temp. Tensile Strength, min. 840MPa/120 ksi Yield Strength, 0.2% offset, min. 735MPa/105 ksi Elongation in 4D, min. 3% Reduction in area, min. 8%
  • the properties for forged material differ depending upon whether the samples are tested longitudinally or transversely, e.g., the properties are not isotropic and the lower values are produced during transverse testing.
  • test specimens comprising material produced in accordance with the present invention
  • ASTM E292 standard combination smooth and notched stress rupture test specimens
  • the specimens were maintained at 650 °C/1200 °F and loaded continuously, after generating an initial axial stress of between about 735 -770 MPa/105 - 110 ksi.
  • the specimens ruptured after at least 23 hours.
  • such nickel base superalloys such as IN 718 are preferably melted and cast m a non-reactive environment, e.g., in the presence of an inert gas or more preferably in a vacuum environment.
  • a preferred manner of die casting the articles is set forth in co-pending application entitled “Method of Making die Cast Articles of High Melting Temperature or Reactive Materials", and “Apparatus for Die Casting High Melting Temperature Materials”, filed on even date herewith and which are each hereby incorporated explicitly herein by reference.
  • a single charge or small batch (less than about 4.5kg/10 pounds) of material is prepared (FIG. 10, step 44). The charge is melted to ensure rapid melting without contaminating the material.
  • the molten material is then poured into a horizontal shot sleeve of a cold chamber-type die casting apparatus, which is also preferably evacuated, so as to partially fill the sleeve.
  • the molten material is then injected into a die, which is preferably unheated, where it solidifies to form the desired article.
  • material to be die cast is melted (step 46 - FIG. 10) in the apparatus 18 illustrated in FIGS. 8 and 9.
  • reactive materials such as superalloys containing reactive elements
  • any gasses in the melting environment may become entrapped in the molten material and result in excess porosity in die cast articles, we prefer to melt the material in a vacuum environment rather than in an inert environment, e.g., argon.
  • the material is melted in a melt chamber 20 coupled to a vacuum source 22 in which the chamber is maintained at a pressure of less than 100 ⁇ m, and preferably less than 50 ⁇ m.
  • ISR induction skull remelting or melting
  • material is melted in a crucible defined a plurality of metal (typically copper) fingers retained in position next to one another.
  • the crucible is surrounded by an induction coil coupled to a power source 26.
  • the fingers include passages for the circulation of cooling water from and to a water source (not shown), to prevent melting of the fingers.
  • the field generated by the coil passes through the crucible, and heats and melts material located in the crucible.
  • the field also serves to agitate or stir the molten metal.
  • a thin layer of the material freezes on the crucible wall and forms the skull, thereby minimizing the ability of molten material to attack the crucible.
  • the material is melted with a limited superheat -high enough to ensure that the material remains at least substantially molten until it is injected, but low enough to ensure that rapid solidification occurs upon injection, e.g., so that small grains can be formed.
  • the material may be melted in other manners, such as by vacuum induction melting (VIM), electron beam melting, resistance melting or plasma arc.
  • VIM vacuum induction melting
  • we do not rule out melting bulk material e.g., several charges of material at once, in a vacuum environment and then transferring single charges of molten material into the shot sleeve for injection into the die.
  • any equipment used to transfer the molten material must typically be capable of withstanding high temperatures and be positioned in the vacuum chamber, and consequently the chamber must be relatively large. The additional equipment adds cost, and the correspondingly large vacuum chamber takes longer to evacuate thus adversely affecting the cycle time.
  • the crucible In order to transfer molten material from the crucible to a shot sleeve 30 of the apparatus (step 48 - FIG. 10), the crucible is mounted for translation (arrow 32 in FIG. 9), and also for pivotal movement (arrow 33 of FIG. 8) about a pouring axis (not shown), and in turn is mounted to a motor (also not shown) for rotating the crucible to pour molten material from the crucible through a pour hole 32 of the shot sleeve 30, with or without a pour cup or funnel coupled to the sleeve. Translation occurs between the melt chamber 20 in which material is melted and a position in a separate vacuum chamber 34 in which the shot sleeve is located.
  • the pour chamber 34 is also maintained as a non-reactive environment, preferably a vacuum environment at a pressure less than 100 ⁇ m, and more preferably less than 50 ⁇ m.
  • the melt chamber 20 and pour chamber 34 are separated by a gate valve or other suitable means (not shown) to minimize the loss of vacuum in the event that one chamber is exposed to atmosphere, e.g., to gain access to a component in the particular chamber.
  • the molten material is transferred from the crucible 24 into the shot sleeve 30 through a pour hole 34.
  • the shot sleeve 30 is coupled to a multipart, reusable die 36, which defines a die cavity 38.
  • a sufficient amount of molten material is poured into the shot sleeve to fill the die cavity, which may include one part or more than one part.
  • the illustrated die 36 includes two parts. 36a, 36b, which cooperate to define the die cavity 38, for example in the form of a compressor airfoil for a gas turbine engine.
  • the die 36 is also coupled to the vacuum source, to enable evacuation of the die prior to injection of the molten metal, and may be enclosed in a separate vacuum chamber.
  • One part of the two parts 36a. 36b of the die is fixed, while the other part is movable relative to the one part, for example by a hydraulic assembly (not shown).
  • the dies preferably include ejector pins (not shown) to facilitate ejecting solidified material from the die.
  • the die may be composed of various materials, and should have good thermal conductivity. and be relatively resistant to erosion and chemical attack from injection of the molten material.
  • a comprehensive list of possible materials would be quite large, and includes materials such as metals, ceramics, graphite and metal matrix composites.
  • tool steels such as H13 and V57, molybdenum and tungsten based materials such as TZM and Anviloy, copper based materials such as copper beryllium alloy "Moldmax"- high hardness, cobalt based alloys such as F75 and L605, nickel based alloys such as IN 100 and Rene 95, iron base superalloys and mild carbon steels such as 1018.
  • Selection of the die material is critical to producing articles economically, and depends upon the complexity and quantity of the article being cast, as well as on the current cost of the component.
  • Each die material has attributes that makes it desirable for different applications.
  • mild carbon steels and copper beryllium alloys are preferred due to their relative ease of machining and fabricating the die.
  • Refractory metal such as tungsten and molybdenum based materials are preferred for higher cost, higher volume applications due to their good strength at higher temperatures.
  • Cobalt based and nickel based alloys and the more highly alloyed tool steels offer a compromise between these two groups of materials.
  • the use of coatings and surface treatments may be employed to enhance apparatus performance and the quality of resulting parts.
  • the die may also be attached to a source of coolant such as water or a source of heat such as oil (not shown) to thermally manage the die temperature during operation.
  • a die lubricant may be applied to one or more selected parts of the die and the die casting apparatus. Any lubricant should generally improve the quality of resultant cast articles, and more specifically should be resistant to thermal breakdown, so as not to contaminate the material being injected.
  • Molten metal is then transferred from the crucible to the shot sleeve.
  • a sufficient amount of molten metal is poured into the shot sleeve to fill the die cavity and associated runners, biscuit, other cavities. Since IN 718 does not "can" to the extent that titanium alloys do, it is possible to fill the shot sleeve. However, we have produced good quality castings where the sleeve is less than 50% filled, less than about 40% filled, and less than about 30% filled.
  • An injection device such as a plunger 40 cooperates with the shot sleeve 30 and hydraulics or other suitable assembly (not shown) drive the plunger in the direction of arrow 42, to move the plunger between the position illustrated by the solid lines and the position indicated by dashed lines. and thereby inject the molten material from the sleeve 30 into the die cavity 38 (step 50 - FIG. 15).
  • the plunger and sleeve cooperate to define a volume that is substantially greater than the amount of molten material that will be injected.
  • the volume is at least twice the volume of material to be injected, more preferably at least about three times. Accordingly, the volume of molten material transferred from the crucible to the sleeve.
  • any material or skin that solidifies on the sleeve forms only a partial cylinder, e.g., an open arcuate surface, and is more easily scraped or crushed during metal injection. and reincorporated into the molten material.
  • plunger speeds of between about 0.77 m/s - 30 inches per second (ips) and 7.7 m/s -- 300 ips, and currently prefer to use a plunger speed of between about 1.3 - 4.5 m/s -- 50 - 175 inches per second (ips).
  • the plunger is typically moved at a pressure of at least 8.4 MPa/1200 psi, and more preferably at least 10.5 MPa/1500 psi.
  • the plunger begins to transfer pressure to the metal.
  • the pressure exerted on the metal is then intensified, preferably to at least 3.5 MPa/500 psi and more preferably to at least about 10.5 MPa/1500 psi, to ensure complete filling of the mold cavity. Intensification is also performed to minimize porosity, and to reduce or eliminate any material shrinkage during cooling.
  • the ejector pins (not shown) are actuated to eject parts from the die (step 52 - FIG. 10).
  • each article may then be heat treated.
  • the heat treatment includes standard and commercially accepted treatment, such as is disclosed in AMS 5663.
  • Actual heat treatment and HIP parameters may be varied depending upon the desired properties and application for the article and target cycle time for the process, however the temperature, pressure and time used during HIP must be sufficient to eliminate substantially all porosity, and homogenize any residual casting segregation but not to allow significant grain growth.
  • the parts are inspected (step 56 - FIG. 10) using conventional inspection techniques, e.g., by fluorescent penetrant inspection (FPI), radiographic, visual, and after passing inspection may be used or further treated/re-treated if necessary (step 58 - FIG. 10).
  • FPI fluorescent penetrant inspection
  • radiographic visual
  • after passing inspection may be used or further treated/re-treated if necessary (step 58 - FIG. 10).
  • FIG. 13 illustrates die cast IN 718 material after being heated to a temperature of about 1010 °C/1850 ° F for 2 hours, without the pressure, to illustrate the reduction in segregation.
  • Application of an appropriate HIP pressure during this time closes the existing porosity.
  • an IN 718 article as die cast had an average grain size of about ASTM 9, and a percent segregation of about 30% (see the picture to the left of the curve).
  • Samples were treated at temperatures between about 954 - 1121 °C/1750 - 2050 °F, and the treated articles had reduced segregation and average grain sizes that increased with increasing temperatures. The increase in average grain size is enhanced where longer times are used, particularly at higher temperatures.
  • the curve illustrated in FIG. 11 is for die cast IN 718, but other materials may exhibit similar behavior. See, e.g., co-pending application entitled "Die Cast Superalloy Articles".
  • the melting, pouring and injection of material must be performed in a non-reactive environment, and we prefer to perform these operations in a vacuum environment maintained at a pressure preferably less than 100 ⁇ m and more preferably less than 50 ⁇ m.
  • the amount of superheat should be sufficient to ensure that the material remains substantially and completely molten from the time it is poured until it is injected, but also to enable rapid cooling and formation of small grains once injected. Due to the relatively low superheat, molten metal transfer and injection must be rapid enough to occur prior to metal solidification.
  • the resulting microstructure such as grain size appears to correspond to the sectional thickness of the part being cast as well as the die materials utilized and the superheat used, i.e., thinner sections tend to include smaller grains and thicker sections (particularly internal portions of thicker sections) tend to include larger grains.
  • Higher thermal conductivity die materials result in articles having smaller grains, as does use of lower superheats. We believe that this results from relative cooling rates of these sections.
  • the rate at which the plunger is moved, and correspondingly the rate at which material is injected into the mold appears to affect the surface finish of the articles as cast, although the design of the gating as well as the die material may also play a role in combination with the injection rate. Careful control of the post cast thermal processing is required to fully achieve the benefits offered by the relatively fine as die cast microstructure.
  • Die casting provides other significant advantages over forging. The time required to produce a part. from ingot to finished part, is reduced significantly, since there is no need to prepare specially tailored billets of material, and casting broadly is performed in a single step, as opposed to multiple forging operations. In die casting, multiple parts can be produced in a single casting. Die casting enables production of parts having more complex three dimensional shapes, thereby enabling new software design technology to be applied to and exploited in areas such as gas turbine engines and enabling production of more efficient airfoils and other components. We believe that die casting will enable the production of articles having complex shapes utilizing materials that arc difficult or impossible to forge into those shapes. Moreover, die cast parts have greater reproducibility than forged or investment cast articles, and can be produced nearer to their finished shape, and with a superior surface finish, which minimizes post forming finishing operations, all of which also reduces the cost of producing such parts.
  • the preferred heat treatment of the present invention provides advantages.
  • the heat treatment eliminates the adverse effect of casting, e.g., porosity, Laves segregation and other unwanted TCP phases while retaining the fine grain size which provides superior mechanical properties.
  • the treatment enables the elimination of all of the above adverse effects in a single step, thereby enabling savings of cost, time and handling.
  • the present invention provides a heat treatment for reducing or eliminating elemental segregation and TCP phases in die cast IN 718 articles.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Metallurgy (AREA)
  • General Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Crystallography & Structural Chemistry (AREA)
  • Turbine Rotor Nozzle Sealing (AREA)
  • Moulds For Moulding Plastics Or The Like (AREA)
  • Powder Metallurgy (AREA)
  • Mounting, Exchange, And Manufacturing Of Dies (AREA)
  • Manufacture Of Alloys Or Alloy Compounds (AREA)
EP99310535A 1998-12-23 1999-12-23 Method for making die cast nickel-based superalloy articles Expired - Lifetime EP1013781B1 (en)

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UA70300A (ru) 2004-10-15
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ES2216453T3 (es) 2004-10-16
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JP2000192208A (ja) 2000-07-11
KR20000048339A (ko) 2000-07-25
CN1279299A (zh) 2001-01-10
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ATE266103T1 (de) 2004-05-15
EP1013781A3 (en) 2000-07-05
US20020005233A1 (en) 2002-01-17
CN1111207C (zh) 2003-06-11
RU2235798C2 (ru) 2004-09-10
DE69916983T2 (de) 2005-06-09
DE69916983D1 (de) 2004-06-09
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IL133580A (en) 2004-05-12

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