EP1595618B1 - Verlorene Wachsform-Giessverfahren mit Kontaktschicht - Google Patents

Verlorene Wachsform-Giessverfahren mit Kontaktschicht Download PDF

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Publication number
EP1595618B1
EP1595618B1 EP05103895A EP05103895A EP1595618B1 EP 1595618 B1 EP1595618 B1 EP 1595618B1 EP 05103895 A EP05103895 A EP 05103895A EP 05103895 A EP05103895 A EP 05103895A EP 1595618 B1 EP1595618 B1 EP 1595618B1
Authority
EP
European Patent Office
Prior art keywords
whereof
particles
contact layer
slip
layer
Prior art date
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Active
Application number
EP05103895A
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English (en)
French (fr)
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EP1595618A1 (de
Inventor
Arnaud Biramben
Christian Marty
Patrice Ragot
Jean-Christophe Husson
Patrick Chevalier
Serge Fargeas
Franck Truelle
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
SNECMA SAS
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Publication date
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Publication of EP1595618A1 publication Critical patent/EP1595618A1/de
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Classifications

    • 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

Definitions

  • the present invention relates to the manufacture of parts such as metal vanes with complex geometries according to the technique known as lost-wax foundry.
  • turbofan bladders such as parts of rotors or stators, or structural parts according to this technique
  • it is first made a model wax or other equivalent material easily removable later. If necessary, we group together several models into one cluster.
  • a ceramic mold is made around this model by dipping in a first slip to form a first layer of material in contact with its surface. The surface of this layer is sanded in order to reinforce it and facilitate the attachment of the next layer, and the assembly is dried: this constitutes the stuccage and drying operations respectively.
  • the soaking operation is then repeated in slips of possibly different compositions, an operation always associated with the successive operations of stuccage and drying.
  • a ceramic shell made of a plurality of layers is thus produced.
  • the slips are composed of particles of ceramic materials, in particular a flour, such as alumina, mullite, zircon or other, with a mineral colloidal binder and adjuvants where appropriate depending on the desired rheology.
  • a flour such as alumina, mullite, zircon or other
  • adjuvants where appropriate depending on the desired rheology.
  • It may be a wetting agent, a fluidizer or a texturizer depending, for the latter, the desired thickness for the deposit.
  • the carapace mold is then dewaxed, which is an operation by which the material constituting the original model is removed. After elimination of the model, we obtain a ceramic mold whose cavity reproduces all the details of the model. The mold then undergoes heat treatment at high temperature or "cooking" which gives it the necessary mechanical properties. The shell mold is thus ready for the manufacture of the metal part by casting.
  • the next step is to sink a molten metal into the mold cavity and then to solidify it.
  • solidification techniques there are currently several solidification techniques, and therefore several casting techniques, depending on the nature of the alloy and the expected properties of the part resulting from the casting. It may be directed solidification with columnar structure (DS), directed solidification with monocrystalline structure (SX) or equiaxed solidification (EX) respectively.
  • DS columnar structure
  • SX monocrystalline structure
  • EX equiaxed solidification
  • the shell is broken by a shake-out operation, and the manufacturing of the metal part is completed.
  • each carapace must have specific properties that ensure the desired type of solidification.
  • the shells can be made from different fillers, based on silico-aluminous, silica-zircon or silica.
  • the first layer for each of these carapaces plays a vital role. It forms the interface between the shell mold and the cast alloy. It must, in the case of a solidification directed columnar or monocrystalline structure, be non-reactive with the cast alloy. In the case of equiaxial solidification, it must allow the equiaxial germination of the grains. Furthermore, the integrity of this contact layer determines the final quality of the casting, in terms of surface condition in particular.
  • the first layer must meet certain requirements in order to avoid defects such as ceramic decohesion and surface defects.
  • the decohesions of the contact layer before or during the casting can generate harmful marks on parts.
  • the surface defects result from excessive micro-porosity of the contact layer which generates surpluses forming reliefs on the surface of the parts.
  • the major surface defects are often the result of a surface capillary phenomenon at the interface between the wax model and the first layer.
  • the grains of sand form stacks, which have many capillaries.
  • the depression promotes a capillary rise of the slip towards the stucco until the column of liquid thus formed restores the pressure difference. This results in the formation of a cavity withdrawal zone which leads to the formation of surface defects. This phenomenon is accentuated by a first layer of too low thickness.
  • the properties of the contact layer must therefore make it possible to find a compromise between these antagonistic characteristics, in order to overcome any defects on parts.
  • the composition of the slip it is possible to fulfill the objectives assigned for all foundry molds, the properties of which satisfy the casting conditions in particular meeting the constraints of solidification processes DS and SX.
  • the contact layer is not reactive to cast superalloys.
  • the slip is advantageously composed of mullite flour in an amount of between 65 and 90% by weight, without zircon.
  • the sand particles or "stuccos" for this contact layer are formed from mullite and not zircon grains.
  • additives in the slip allows to control wax deposits and ensure optimal characteristics in terms of thickness and distribution on parts.
  • the binder is a water-based mineral colloidal solution, such as colloidal silica, and not an alcohol base binder.
  • the method of manufacturing the shell molds comprises a first step of manufacturing the model in wax or in another equivalent material known in the field.
  • the most commonly known is wax.
  • the cluster models can be grouped so that they can be simultaneously.
  • the models are shaped to the dimensions of the final pieces, to the shrinkage near the alloys.
  • the carapace manufacturing steps are preferably carried out by a robot whose movements are programmed to have an optimal action on the quality of the deposits made, and to overcome the geometric aspect of the various blades.
  • slips are prepared in which the models or the cluster are quenched successively to deposit ceramic materials.
  • the covered model undergoes a phase of dewatering and then topping.
  • Sand stucco grains are then sprinkled to avoid disturbing the thin layer of contact.
  • Mullite is used, the particle size of which in this first layer is fine. It is between 80 and 250 microns. The surface condition of the final pieces depends in part.
  • the layer is dried.
  • the dipping is then carried out in a second slip to form a so-called "intermediate" layer.
  • the model is then quenched in a third slip to form the layer 3 which is the first so-called "reinforcing" layer.
  • the stucco is then applied and dried.
  • the soaking operations are repeated in the third slip, stucco and drying to obtain the desired shell thickness.
  • a glazing operation is carried out for the last layer.
  • the second and third slip may comprise a mixture of alumina and mullite flours in amounts of from 45 to 95% by weight, and mullite grains in amounts of from 0 to 25% by weight.
  • the soaked layers for the different layers are made in different ways and adapted to obtain a uniform distribution of thicknesses and to avoid the formation of bubbles, especially in enclosed areas.
  • the carapace can thus comprise from 5 to 12 layers.
  • the baking cycle of the molds comprises a temperature rise phase during a given period, a plateau at the baking temperature and a cooling phase.
  • the firing cycle is chosen to optimize the mechanical properties of the shells so as to allow cold handling without risk of breakage, and so as to minimize their sensitivity to thermal shocks that can be generated during the various stages of casting.
  • This contact layer can be associated with all types of layers as required, even if necessary with layers made from zircon particles.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
  • Mold Materials And Core Materials (AREA)

Claims (10)

  1. Verfahren zur Herstellung einer keramischen Maskenform mit mehreren Schichten, wozu mindestens eine Kontaktschicht gehört, ausgehend von einem Modell einer herzustellenden Turbomaschinenschaufel aus Wachs oder einem anderen ähnlichen Material, umfassend das Härten des Modells in einem ersten Gießschlicker, der Keramikteilchen und ein Bindemittel enthält, um die Kontaktschicht zu bilden, das Abscheiden der Sandteilchen auf der Schicht und das Trocknen derselben, dadurch gekennzeichnet, dass die Keramikteilchen des ersten Gießschlickers Mullitteilchen sind, wobei der Gießschlicker ein Benetzungsmittel, einen Verflüssiger und einen Strukturfestiger umfasst und die Sandteilchen aus Mullitkörnern gebildet sind, deren Körnung zwischen 80 und 250 Mikrometern liegt.
  2. Verfahren nach Anspruch 1, wobei die Keramikteilchen kein Zirkon umfassen.
  3. Verfahren nach Anspruch 1, wobei das Benetzungsmittel aus Polyalken-Fettalkoholen oder Alkoxylat-Alkoholen gewählt wird.
  4. Verfahren nach Anspruch 3, wobei der Verflüssiger aus Aminosäuren, Ammoniumpolyacrylaten oder dreisäurigen Carboxylen mit Alkoholgruppen gewählt wird.
  5. Verfahren nach Anspruch 1, wobei der Strukturfestiger aus Ethylenoxidpolymeren, Xanthangummi oder Guargummi gewählt wird.
  6. Verfahren nach Anspruch 1, wobei das Bindemittel auf mineralischen kolloidalen Lösungen auf Wasserbasis, insbesondere auf kolloidaler Kieselerde basiert.
  7. Verfahren nach Anspruch 1, wobei die Sandteilchen durch Aufstreuen aufgetragen werden.
  8. Verfahren nach Anspruch 1, wobei der Gießschlicker ein Mullitmehl in einer Menge zwischen 65 und 80 Gewichtsprozent umfasst.
  9. Verwendung einer Maskenform nach einem der vorhergehenden Ansprüche zur Herstellung einer Turbomaschinenschaufel mit gelenkter Erstarrung säulenförmiger Struktur.
  10. Verwendung einer Maskenform nach einem der Ansprüche 1 bis 8 zur Herstellung einer Turbomaschinenschaufel mit gelenkter Erstarrung monokristalliner Struktur.
EP05103895A 2004-05-12 2005-05-10 Verlorene Wachsform-Giessverfahren mit Kontaktschicht Active EP1595618B1 (de)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
FR0405145A FR2870148B1 (fr) 2004-05-12 2004-05-12 Procede de fonderie a cire perdue avec couche de contact
FR0405145 2004-05-12

Publications (2)

Publication Number Publication Date
EP1595618A1 EP1595618A1 (de) 2005-11-16
EP1595618B1 true EP1595618B1 (de) 2010-11-24

Family

ID=34939771

Family Applications (1)

Application Number Title Priority Date Filing Date
EP05103895A Active EP1595618B1 (de) 2004-05-12 2005-05-10 Verlorene Wachsform-Giessverfahren mit Kontaktschicht

Country Status (6)

Country Link
US (1) US7370688B2 (de)
EP (1) EP1595618B1 (de)
JP (1) JP4918227B2 (de)
CA (1) CA2507171C (de)
DE (1) DE602005024887D1 (de)
FR (1) FR2870148B1 (de)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102016123051A1 (de) * 2016-11-29 2018-05-30 HÜTTENES-ALBERTUS Chemische Werke Gesellschaft mit beschränkter Haftung Aminosäure enthaltende Formstoffmischung zur Herstellung von Formkörpern für die Gießereiindustrie

Families Citing this family (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20140190846A1 (en) * 2011-07-29 2014-07-10 Dsm Ip Assets B.V Medical device comprising a wetted hydrophilic coating
CN107199309B (zh) * 2017-06-08 2020-02-07 淄博金东机械制造有限公司 一种铸件模组制壳工艺
FR3068271B1 (fr) 2017-06-29 2021-12-10 Safran Aircraft Engines Procede de fonderie avec coulee en moule chaud
FR3085286B1 (fr) 2018-08-28 2021-08-06 Safran Aircraft Engines Procede de fabrication d'une eprouvette a plusieurs couches ceramiques, eprouvette obtenue par la mise en œuvre d'un tel procede de fabrication et utilisation d'une telle eprouvette pour un essai de compression uniaxiale a chaud
CN109261901B (zh) * 2018-11-26 2021-01-05 惠州市吉邦精密技术有限公司 一种易溃散型壳的制壳工艺
FR3103400B1 (fr) 2019-11-21 2022-08-19 Safran Aircraft Engines Moule de fonderie, procede de fabrication du moule et procede de fonderie

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EP0939431B1 (de) * 1996-09-30 2009-05-20 Hitachi Chemical Co., Ltd. Schleifmittel aus cerium oxid und verfahren zum schleifen von substraten
BR9807084A (pt) * 1997-01-27 2000-04-18 Allied Signal Inc Processo para a produção de cadinhos e moldes integrados para fundições de metais reativos
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Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102016123051A1 (de) * 2016-11-29 2018-05-30 HÜTTENES-ALBERTUS Chemische Werke Gesellschaft mit beschränkter Haftung Aminosäure enthaltende Formstoffmischung zur Herstellung von Formkörpern für die Gießereiindustrie
WO2018099887A1 (de) 2016-11-29 2018-06-07 HÜTTENES-ALBERTUS Chemische Werke Gesellschaft mit beschränkter Haftung AMINOSÄURE ENTHALTENDE FORMSTOFFMISCHUNG ZUR HERSTELLUNG VON FORMKÖRPERN FÜR DIE GIEßEREIINDUSTRIE

Also Published As

Publication number Publication date
DE602005024887D1 (de) 2011-01-05
JP2005349472A (ja) 2005-12-22
JP4918227B2 (ja) 2012-04-18
US7370688B2 (en) 2008-05-13
EP1595618A1 (de) 2005-11-16
CA2507171A1 (fr) 2005-11-12
FR2870148B1 (fr) 2006-07-07
FR2870148A1 (fr) 2005-11-18
CA2507171C (fr) 2013-07-09
US20050252633A1 (en) 2005-11-17

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