EP1595620B1 - Verlorene Form Giessverfahren - Google Patents

Verlorene Form Giessverfahren Download PDF

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Publication number
EP1595620B1
EP1595620B1 EP05103958A EP05103958A EP1595620B1 EP 1595620 B1 EP1595620 B1 EP 1595620B1 EP 05103958 A EP05103958 A EP 05103958A EP 05103958 A EP05103958 A EP 05103958A EP 1595620 B1 EP1595620 B1 EP 1595620B1
Authority
EP
European Patent Office
Prior art keywords
mullite
layer
layers
solidification
slip
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
EP05103958A
Other languages
English (en)
French (fr)
Other versions
EP1595620A1 (de
Inventor
Arnaud Biramben
Patrick Calero
Patrick Chevalier
Jean-Christophe Husson
Christian Marty
Patrice Ragot
Pierre Richard
Franck Truelle
Isabelle Valente
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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Filing date
Publication date
Application filed by SNECMA SAS filed Critical SNECMA SAS
Publication of EP1595620A1 publication Critical patent/EP1595620A1/de
Application granted granted Critical
Publication of EP1595620B1 publication Critical patent/EP1595620B1/de
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/12—Treating moulds or cores, e.g. drying, hardening

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
  • 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 pour a molten metal into the mold cavity and then to the solidify.
  • 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 directed solidification with monocrystalline structure
  • EX equiaxed solidification
  • the shell is broken by a shaking operation, and the manufacture of the metal part is completed.
  • each carapace must have specific properties that ensure the desired type of solidification.
  • equiaxed solidification several different processes can be implemented, one using an ethyl silicate binder, another using a colloidal silica binder.
  • the shells can be made from different fillers, based on silico-aluminous, silica-zircon or silica.
  • the invention achieves these objectives with the following method.
  • the method is characterized in that the ceramic particles of the slips comprise a refractory oxide or a mixture of refractory oxides without zircon, none of the layers comprising zircon so that the shell mold is not even weakly, radioactive.
  • the slip for the formation of the reinforcing layers is much more fluid than the second slip.
  • the binder for the various slips is a colloidal mineral solution such as colloidal silica.
  • the stucco grains for the contact, intermediate and reinforcement layers are made from mullite grains and not zircon grains.
  • the stuccage operations are carried out with stucco grains covering a size range between 80 and 1000 microns.
  • the stucco is preferably applied by dusting for the first layers, and is preferably applied by fluidized bed, for the layers from the fourth.
  • Stucco is applied automatically, so that the movements of the robot can achieve a shell mold having a porosity after baking, between 20 and 35%. The more porous the shell is, the more it reduces its sensitivity to thermal shocks such as those produced during different types of casting.
  • the mold baking cycle comprises heating to a temperature of between 1000 and 1150 ° C, preferably between 1030 ° C and 1070 ° C.
  • the first slip can be formed from mullite flours and alumina without zircon, with or without germinating.
  • the contact layer is composed mainly of mullite flour in an amount of between 40 and 80% by weight, optionally of alumina flour, a binder based on colloidal silica. , and organic adjuvants.
  • the contact layer is composed of a mixture of alumina flours and mullite in amounts respectively of between 40 and 80% by weight and between 2 and 30% by weight, the remainder comprising a binder based on colloidal silica, a germinator, and organic adjuvants.
  • the second and third slip are common to any solidification process, and comprise a mixture of alumina and mullite flours in an amount of between 45 and 95% by weight, and mullite grains in an amount of between 0 and 25% by weight.
  • the mold structure thus defined finds, indifferently, a use for the manufacture of a part with solidification of directed type with a columnar structure, the contact layer being formed mainly from a mullite flour, for the manufacture of a monocrystalline structured type solidification-type part, the contact layer being formed predominantly from a mullite flour or else for producing a piece with equiaxed type solidification, the contact layer being formed from a mixture of alumina flour and mullite.
  • the invention also relates to a method for manufacturing parts by casting of molten metal according to which, regardless of the type of solidification, directed with a columnar structure, directed with monocrystalline or equiaxed structure, molds having a skeleton of shells are used.
  • common intermediate layer and common reinforcement layer.
  • the invention also relates to an installation for the manufacture of parts by casting a molten metal in a shell mold comprising a mold manufacturing station and casting stations for different solidifications, said stations being fed with molds having identical reinforcement layers.
  • the method of manufacturing shell molds for common use in all types of parts comprises a first step of manufacturing the wax model or other equivalent material known in the art.
  • the most commonly known is wax.
  • the clustered models can be grouped so that several can be manufactured 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 common to all types of parts, programmed to have an optimal action on the quality of the deposits made, and to overcome the geometrical aspect of the different blading.
  • slips are prepared in which the models or the cluster are successively quenched to deposit a ceramic material.
  • the covered model undergoes a phase of dewatering and then topping. Then, stucco grains are applied by dusting so as not to disturb 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 No. 1 layer is dried.
  • a stucco is deposited by dusting and dried.
  • mullite is used whose particle size is medium. It can be between 120 and 1000 microns.
  • the state of porosity of the shells finally depends on it.
  • the model is then quenched in a third slip to form the layer No. 3 which is the first so-called reinforcing layer.
  • the identical stucco is then applied to the No. 2 layer by dusting and dried.
  • the soaking operations are repeated in the third slip, stuccage and drying to form the layers of "reinforcement".
  • the stuccage is carried out by fluidized bed.
  • a glazing operation is performed which does not include a stuccage operation.
  • the carapace in final can consist of 5 to 12 layers.
  • the soaked layers for the different layers are made in different ways and are adapted to obtain a uniform distribution of thicknesses and to avoid the formation of bubbles, especially in enclosed areas.
  • Hardening programs are optimized for each type of layer, to overcome the geometric aspect of the different types of parts, and are therefore common to all references.
  • the interlayer drying range is optimized for each type of layer, in order to overcome the geometrical appearance of the different types of parts.
  • the range is therefore common.
  • the range makes it possible, for each type of layer, to dry molds with geometries as different as moving blades, distributors, or structural parts.
  • the mussel baking cycle is the same for all types of solidification, and thus also eliminates the type of part. It includes a temperature rise phase, a bearing at the baking temperature and a cooling phase.
  • the cooking 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 the sensitivity to thermal shocks that can be generated during the various stages of casting.

Landscapes

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

Claims (17)

  1. Verfahren zur Herstellung einer keramischen Maskenform mit mehreren Schichten, darunter mindestens eine Kontaktschicht, eine Zwischenschicht und mehrere Verstärkungsschichten, ausgehend von einem Modell des herzustellenden Bauteils aus Wachs oder einem anderen ähnlichen Material, das darin besteht, die folgenden aufeinanderfolgenden Vorgänge durchzuführen:
    Eintauchen in einen ersten Schlamm, der Keramikpartikel und ein Bindemittel enthält, Aufbringen von Sandpartikeln auf die Schicht und deren Trocknen, um die Kontaktschicht zu formen,
    Eintauchen in einen zweiten Schlamm, der Keramikpartikel und ein Bindemittel enthält, Aufbringen von Sandpartikeln auf die Schicht und deren Trocknen, um die Zwischenschicht zu formen,
    Eintauchen in mindestens einen dritten Schlamm, der Keramikpartikel und ein Bindemittel enthält, Aufbringen von Sandpartikeln auf die Schicht, deren Trocknen, um eine Verstärkungsschicht zu formen, wobei das Formen von Verstärkungsschichten wiederholt wird, bis eine festgelegte Maskenformdicke erhalten wird,
    dadurch gekennzeichnet, dass die Keramikpartikel der Schlämme ein feuerfestes Oxid oder eine Mischung aus feuerfesten Oxiden ohne Zirkon enthalten, wobei keine der Schichten Zirkon enthält, damit die Maskenform nicht einmal geringfügig radioaktiv ist.
  2. Verfahren nach Anspruch 1, gemäß dem das feuerfeste Oxid Mullit oder Aluminiumoxid ist.
  3. Verfahren nach Anspruch 1 oder 2, gemäß dem die Bindemittel für die verschiedenen Schlämme auf der Basis von mineralischen kolloidalen Lösungen sind, insbesondere kolloidalem Siliciumdioxid.
  4. Verfahren nach den Ansprüchen 1, 2 oder 3, gemäß dem die Sandpartikel aus Körnern von feuerfesten Oxiden ohne Zirkon bestehen, insbesondere aus Mullitkörnern.
  5. Verfahren nach Anspruch 4, gemäß dem die Körner eine Körnchengröße zwischen 80 und 1000 Mikron haben.
  6. Verfahren nach Anspruch 4 oder 5, gemäß dem für bestimmte Schichten die Sandpartikel durch Aufstreuen aufgebracht werden, vorzugsweise für die drei ersten Schichten.
  7. Verfahren nach Anspruch 4, 5 und 6, gemäß dem für bestimmte Schichten die Sandpartikel durch Wirbelschichtverfahren aufgebracht werden, vorzugsweise für die Schichten ab der vierten.
  8. Verfahren nach einem der Ansprüche 4 bis 7, gemäß dem die Sandpartikel so aufgebracht werden, dass die Maske eine Porosität nach dem Brennen hat, die zwischen 20 und 35% liegt.
  9. Verfahren nach Anspruch 1, gemäß dem das Trocknen zwischen zwei aufeinanderfolgenden Schichten gemäß dem gleichen Umfang durchgeführt wird, unabhängig vom Bauteil und seiner Geometrie.
  10. Verfahren nach Anspruch 1, gemäß dem das Eintauchen durch einen Roboter durchgeführt wird, der so programmiert ist, dass die Bewegungen des Roboters unabhängig von der Geometrie des Bauteils die gleichen sind.
  11. Verfahren nach einem der vorhergehenden Ansprüche, gemäß dem das Aufbringen der Sandpartikel auf die Form automatisch von einem Roboter derart durchgeführt wird, dass die Bewegungen des Roboters unabhängig von der Geometrie des Bauteils die gleichen sind.
  12. Verfahren nach einem der vorhergehenden Ansprüche, gemäß dem der Brennzyklus der endgültigen Maskenform ein einziger ist, unabhängig vom Bauteil, und ein Erhitzen bis auf eine Temperatur zwischen 1000 und 1150°C, vorzugsweise zwischen 1030 und 1070°C, enthält.
  13. Verfahren nach einem der vorhergehenden Ansprüche, gemäß dem der erste Schlamm eine andere Zusammensetzung aus Aluminiumoxid und aus Mullit hat, je nachdem, ob das Herstellungsverfahren des Bauteils mit gerichteter oder mit äquiaxialer Erstarrung ist.
  14. Verfahren nach einem der vorhergehenden Ansprüche, gemäß dem der zweite und dritte Schlamm eine Mischung aus Aluminiumoxid- und Mullitmehlen und aus Mullitkörnern enthalten und jedem gerichteten oder äquiaxialen Erstarrungsverfahren gemeinsam sind.
  15. Verfahren nach Anspruch 13, gemäß dem der erste Schlamm für eine gerichtete Erstarrung mehrheitlich Mullitmehl in einer Menge zwischen 40 und 80 Gew.-%, ggf. Aluminiumoxidmehl, ein Bindemittel auf der Basis von kolloidalem Siliciumdioxid und organische Zusatzmittel enthält.
  16. Verfahren nach Anspruch 13, gemäß dem der erste Schlamm für eine äquiaxiale Erstarrung eine Mischung aus Aluminiumoxid- und Mullitmehlen in Mengen, die zwischen 40 und 80 Gew.-% bzw. zwischen 2 und 30 Gew.-% liegen, ein Bindemittel auf der Basis von kolloidalem Siliciumdioxid, einen Keimbildner und organische Zusatzmittel enthält.
  17. Verfahren nach Anspruch 14, gemäß dem der zweite und dritte Schlamm allen Erstarrungsverfahren gemeinsam sind und eine Mischung aus Aluminiumoxid- und Mullitmehlen in einer Menge zwischen 45 und 95 Gew.-% und Mullitkörner in einer Menge zwischen 0 und 25 Gew.-% enthalten.
EP05103958A 2004-05-12 2005-05-11 Verlorene Form Giessverfahren Expired - Lifetime EP1595620B1 (de)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
FR0405143 2004-05-12
FR0405143A FR2870147B1 (fr) 2004-05-12 2004-05-12 Procede de fonderie a cire perdue

Publications (2)

Publication Number Publication Date
EP1595620A1 EP1595620A1 (de) 2005-11-16
EP1595620B1 true EP1595620B1 (de) 2011-07-20

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EP05103958A Expired - Lifetime EP1595620B1 (de) 2004-05-12 2005-05-11 Verlorene Form Giessverfahren

Country Status (5)

Country Link
US (1) US7318466B2 (de)
EP (1) EP1595620B1 (de)
JP (1) JP4937528B2 (de)
CA (1) CA2507170C (de)
FR (1) FR2870147B1 (de)

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EP1935530A1 (de) * 2006-12-21 2008-06-25 Siemens Aktiengesellschaft Verfahren zur Herstellung einer keramischen Formschale und Verwendung derselben
JP5178366B2 (ja) * 2008-07-14 2013-04-10 伊藤忠セラテック株式会社 精密鋳造用鋳型製造用スタッコ材及びそれを用いた精密鋳造用鋳型
US8307881B2 (en) * 2009-01-06 2012-11-13 General Electric Company Casting molds for use in directional solidification processes and methods of making
CN104646633B (zh) * 2013-11-20 2017-06-30 沈阳工业大学 局部可自由伸缩的单晶叶片用复杂结构陶瓷型芯制备工艺
JP6317995B2 (ja) * 2014-05-08 2018-04-25 伊藤忠セラテック株式会社 精密鋳造鋳型製造用スラリーのフィラー材及びそれを用いて得られたスラリー並びに精密鋳造鋳型
JP2016002572A (ja) * 2014-06-18 2016-01-12 伊藤忠セラテック株式会社 精密鋳造鋳型製造用スラリー組成物及びその製造方法
JP6368596B2 (ja) * 2014-09-11 2018-08-01 伊藤忠セラテック株式会社 精密鋳造鋳型製造用スラリー組成物及びその製造方法
FR3068271B1 (fr) 2017-06-29 2021-12-10 Safran Aircraft Engines Procede de fonderie avec coulee en moule chaud
FR3071423B1 (fr) 2017-09-22 2019-10-18 Safran Barbotine de fonderie
CN108115088B (zh) * 2017-12-23 2020-01-21 青田保俐铸造有限公司 一种石膏复合聚合物粘性砂浆的熔模型壳铸造工艺
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
FR3103400B1 (fr) 2019-11-21 2022-08-19 Safran Aircraft Engines Moule de fonderie, procede de fabrication du moule et procede de fonderie
FR3144930A1 (fr) * 2023-01-12 2024-07-19 Safran Procédé de fabrication d'un moule comprenant des particules fissurantes
FR3145299B1 (fr) 2023-01-27 2025-10-24 Safran Aircraft Engines Moule de fonderie
CN117139559A (zh) * 2023-08-30 2023-12-01 中国机械总院集团沈阳铸造研究所有限公司 一种尺寸稳定的大型陶瓷型壳制作方法
CN117139560A (zh) * 2023-08-30 2023-12-01 中国机械总院集团沈阳铸造研究所有限公司 定向或单晶高温合金熔模铸造用惰性陶瓷型壳制备方法

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Also Published As

Publication number Publication date
CA2507170A1 (fr) 2005-11-12
JP2005324253A (ja) 2005-11-24
CA2507170C (fr) 2012-12-11
US20050252634A1 (en) 2005-11-17
FR2870147A1 (fr) 2005-11-18
EP1595620A1 (de) 2005-11-16
US7318466B2 (en) 2008-01-15
JP4937528B2 (ja) 2012-05-23
FR2870147B1 (fr) 2007-09-14

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