EP1920858A1 - Procédé de fabrication d'un moule - Google Patents

Procédé de fabrication d'un moule Download PDF

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Publication number
EP1920858A1
EP1920858A1 EP08000499A EP08000499A EP1920858A1 EP 1920858 A1 EP1920858 A1 EP 1920858A1 EP 08000499 A EP08000499 A EP 08000499A EP 08000499 A EP08000499 A EP 08000499A EP 1920858 A1 EP1920858 A1 EP 1920858A1
Authority
EP
European Patent Office
Prior art keywords
wall
mold
recess
model
component
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
EP08000499A
Other languages
German (de)
English (en)
Other versions
EP1920858B1 (fr
Inventor
Thomas Beck
Georg Dr. Bostanjoglo
Uwe Dr. Paul
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.)
Siemens AG
Original Assignee
Siemens AG
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Siemens AG filed Critical Siemens AG
Priority to DE502004009738T priority Critical patent/DE502004009738D1/de
Publication of EP1920858A1 publication Critical patent/EP1920858A1/fr
Application granted granted Critical
Publication of EP1920858B1 publication Critical patent/EP1920858B1/fr
Not-in-force legal-status Critical Current
Anticipated expiration legal-status Critical

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C7/00—Patterns; Manufacture thereof so far as not provided for in other classes
    • B22C7/02—Lost patterns
    • 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
    • B22C9/10—Cores; Manufacture or installation of cores
    • B22C9/108—Installation of cores

Definitions

  • the invention relates to a method for producing a casting mold according to claim 1.
  • Formed as a hollow body components with complex shaped geometries and complex through-holes in the region of an outer wall of the component can be prepared in various ways.
  • a casting mold is produced from a wax model of the component, which at least in part represents the negative of the component to be produced, in that the wax model is covered with ceramic or a sand mold.
  • the object is achieved by a method for producing a casting mold according to claim 1.
  • a mold which has corresponding projections, which at least partially represent the negative of a hole.
  • FIG. 1 1 shows a component 1 which, for example, has a cavity 31 at least in part of its volume and is connected to the mold 16 (FIG. Fig. 2, 3, 4 . 5 ) can be produced.
  • the component 1 has at least one component wall 4, 4 ', in particular outer component walls 4, 4'.
  • at least one hole 13, in this case a through hole 13, is formed in the wall 4.
  • the hole 13 may also be a blind hole.
  • the component 1 may be metallic or ceramic, for example.
  • it is a turbine component 1 of a gas turbine 100 (FIG. Fig. 15 ) or steam turbine and, for example, a turbine blade 120, 130 (FIG. Fig. 15 . 17 ) or a heat shield element 155 (FIG. Fig. 16 ), which consists for example of an iron-, nickel- or cobalt-based superalloy.
  • through holes 13 are provided, for example, as cooling air holes 13 to cool the component 1 by film cooling.
  • the through hole 13 has, for example, a round or oval-shaped hole part 7, which widened from the cavity 31 to the outer surface 11 of the wall 4 to a diffuser 10, so that there the hole 13 deviates from the shape of the hole part 7.
  • the mold 16 for such components 1 with complex shapes of a through hole 13, 7 + 10 can be made easier and faster with the method according to the invention.
  • the wall of the component 1 is, for example, 2 to 6 mm, in particular 3 to 4 mm thick.
  • the hole part 7 has a diameter of 0.3 to 1.2 mm, in particular 0.6 to 0.8 mm.
  • the diffuser 10 is formed on the outer surface 11, for example, trapezoidal and has dimensions of 1.5 to 5mm x 1.5 to 5mm and goes to a depth of 1 to 1.5mm in the component wall 4, 4 'into it.
  • FIG. 2 schematically shows a part of the mold 16, which consists of an inner wall 25, in particular of a core 25 and an outer wall 28.
  • the core 25 forms, for example, a part of the cavity 31 of the component 1.
  • At least one projection 19, 34, 37 is formed of molding material.
  • the projection 19, 34, 37 extends at least over part of the gap between an inner surface 20 of the inner wall 25 and an inner surface 21 of the outer wall 28.
  • the continuous projection 19 extends continuously from the inner surface 20 of the inner wall to the inner surface 21 of the outer wall.
  • the continuous projection 19 is made by pouring ceramics of a through hole 13 in a wax model 43 (FIG. Fig. 7 ) of the component 1 ( Fig. 9 - 15 ).
  • the continuous projection 19 in the gap 26 prevents filling with material 22 during casting, so that after removal of the mold 16 with its inner wall 25 and its outer wall 28 and the continuous projection 19, a through hole 13 results.
  • FIG. 3 shows a further embodiment of a mold 16, which is produced by the method according to the invention.
  • the inner projection 34, 37 'does not extend continuously from an inner surface 20 of the inner wall 25 to an inner surface 21 of the outer wall 28.
  • the inner projection 34 is formed only on the inner surface 20 of the inner wall 25 and extends to a certain distance d to the inner surface 21 of the outer wall 28th
  • the passage opening 13 is not completely formed.
  • material 22 is present after the casting of the component 1.
  • the area is correspondingly thin, in particular membrane-like, so that it can be easily removed in a very short time.
  • the passage opening 13 of the component 1 to be produced is still somewhat closed. This is useful, for example, if subsequently at least one coating is applied to the outer outer surface 11 of the component 1. Since the passage opening 13 is still closed, the passage opening 13 is also not contaminated or narrowed by the material of the coating.
  • the inner projection 34 can also have a support connection 40 (indicated by dashed lines) in order to support the inner projection 34, which projects freely into the intermediate space 26, against the outer wall 28.
  • the support connection 40 is formed smaller in cross section than the cross section of the inner projection 34, 37 ', which is opposite to the outer wall 28.
  • the support connection 40 thus represents only a part of the through hole 13 to be produced.
  • the inner projection 34 may have at its end an advantageous region 37 ', which partly faces the outer projection 37 (FIG. Fig. 4 ) and does not touch the wall 21, but optionally has the support connection 40.
  • the complex shape of the diffuser 10 previously had to be elaborately incorporated into the molded component. This is omitted here for the most part, since only a relatively small upper portion of the diffuser 10 is to be reworked by removing material. Since, in particular, the production of the areas lying deeper in the wall 4 means considerable expenditure, for example in laser guidance, this casting mold 16 has considerable advantages.
  • FIG. 4 shows a further embodiment of a trained mold 16, which was produced by the method according to the invention.
  • the outer protrusion 37 is formed only on the inner surface 21 of the outer wall 28.
  • the outer projection 37 represents the negative 37 of the diffuser 10 of the through-opening 13 to be produced.
  • the diffuser 10 has a more complex geometry than a simple symmetrical hole and would therefore be very complicated to produce with subsequent incorporation.
  • a simply formed hole part 7 ( Fig. 1 ) are incorporated from the diffuser region 10 in the component 1 in the wall 4. This can be done by laser processing or radio wire erosion as well as other methods.
  • a corresponding support connection 40 between the projection 37 and the inner wall 25 may be present (indicated by dashed lines).
  • FIG. 5 shows a further embodiment of a trained mold 16, which was produced by the method according to the invention.
  • an inner projection 34 is formed on the inner surface 20 of the inner wall 25.
  • the inner projection 34 forms a further part of this passage opening 13, namely the area of the hole part 7.
  • the outer projection 37 represents the area of the diffuser 10 of the component 1 to be produced.
  • FIG. 6 shows the top view of an outer wall 28 of a formed mold 16, which was prepared by the method according to the invention.
  • the reference numeral 34 indicates the area from which the hole part 7 will be formed.
  • the reference numeral 37 designates the region of the projection 19, which represents the diffuser region 10 of the through-hole 13 to be produced.
  • FIGS. 7 to 14 show how a mold 16 according to FIGS. 2 to 6 is to produce according to the invention.
  • FIG. 7 shows the inner wall 25 or the core 25 of the mold 16 on which a model 43, in particular made of wax, is present, which corresponds to the geometry of the component 1 to be produced.
  • the inner wall 25 represents the core 25, for example.
  • the model 43 for example, like the component 1 to be produced with the casting mold 16, is a hollow component.
  • the wax model 43 is filled inside with a ceramic 25 ( Fig. 7 ) and externally covered with an outer wall 28 ( Fig. 8 ), in which case the model, in particular a wax model 43, is removed (eg by melting out), so that a casting mold 16 (FIG. Fig. 2, 3, 4 ).
  • a casting mold 16 FIG. Fig. 2, 3, 4
  • material for example, liquid metal is poured into the mold 16, the component 1 is formed.
  • this model 43 at least one recess 46 according to the FIGS. 9 to 12 brought in.
  • This depression 46 is not the cavity of the model 43, but starts, for example, from the surface 58 of the model 43.
  • the depression 46 extends, for example, completely through the model 43, ie as far as the inner wall 25 (FIG. Fig. 9 ) or is formed as a blind hole ( FIG. 10 ), which does not extend to the inner wall 25, that extends over only a part of the wall thickness of the model 43.
  • the depression 46 can be introduced into the model 43 when the inner wall 25 or the core 25 has already been brought together with the model 43 ( Fig. 9 ) or before this happens ( Fig. 12 ).
  • the recess 46 can be made in various ways, for example by drilling, milling or laser machining.
  • this recess 46 may have a slanted hole or oblique "hole” 49 as shown in FIG. 11, 12 is shown.
  • an inner wall 25 or outer wall 28 having an oblique projection can not be produced by molding a ceramic into a corresponding mold and releasing the mold by peeling or loosening.
  • the continuous depression 46 (FIG. Fig. 9, 12th ) with material 52, which corresponds for example to the ceramic of the inner wall 25 or the outer wall 28, completely filled ( Fig. 13 ).
  • material 52 which corresponds for example to the ceramic of the inner wall 25 or the outer wall 28, completely filled ( Fig. 13 ).
  • This can be done together with the introduction or application of the material for the core 25 or for the outer wall 28.
  • a sand mold is often used, which is applied to the surface 58 of the model 43, thereby filling the recesses 46 in the desired manner.
  • the recess 46 can be filled separately with material 52 before applying the outer wall 28.
  • the material 52 is introduced, for example in the form of a slurry and cured, for example, when the outer wall 28 rests, so that the material 52 is in communication with the inner wall 25 or the outer wall 28. Then turn the outer wall 28 to the arrangement according to FIG. 13 is added and the model 43 is removed, a mold 16 is formed according to FIG. 2 out.
  • the continuous recess 46 which extends to the inner wall 25 ( Fig. 9, 12th ), only partially filled with the ceramic 52, leaving a void 55 within the recess 46 ( Fig. 14 ).
  • the core 25 is already present in the model 43, for example.
  • the outer wall 28 is added, the void 55 remains, and when the model 43 is removed, a mold is formed according to FIG FIG. 3 ,
  • the material 52 that has filled in the recess 46 is now an integral part of the mold 16, and is particularly made of the same material that is used for the mold 16 and does not constitute a component.
  • the void 55 is filled with a wax that is removable along with the model 43.
  • the recess 46 may extend only partially in the model 43 ( 10, 11 ) and is completely filled, for example, with a ceramic material 52 ( Fig. 15 ) before the outer wall 28 is applied to the model 43 or with application of the outer wall 28, so that the mold 16 after removal of the model 43 according to FIG. 4 formed.
  • FIG. 16 shows by way of example a gas turbine 100 in a longitudinal partial section.
  • the gas turbine 100 has inside a rotatably mounted about a rotation axis 102 rotor 103, which is also referred to as a turbine runner.
  • a compressor 105 for example a toroidal combustion chamber 110, in particular annular combustion chamber 106, with a plurality of coaxially arranged burners 107, a turbine 108 and the exhaust housing 109.
  • the annular combustion chamber 106 communicates with an annular annular hot gas channel 111, for example.
  • Each turbine stage 112 is formed from two blade rings.
  • a series 125 formed of rotor blades 120 follows.
  • the vanes 130 are attached to the stator 143, whereas the blades 120 of a row 125 are mounted on the rotor 103 by means of a turbine disk 133.
  • On the rotor 103 is coupled to a generator or a work machine (not shown).
  • air 105 is sucked in and compressed by the compressor 105 through the intake housing 104.
  • the compressed air provided at the turbine-side end of the compressor 105 is supplied to the burners 107 where it is mixed with a fuel.
  • the mixture is then burned to form the working fluid 113 in the combustion chamber 110.
  • the working medium 113 flows along the hot gas channel 111 past the guide vanes 130 and the rotor blades 120.
  • the working medium 113 expands in a pulse-transmitting manner so that the rotor blades 120 drive the rotor 103 and drive the machine coupled to it.
  • the components exposed to the hot working medium 113 are subject to thermal loads during operation of the gas turbine 100.
  • the guide vanes 130 and rotor blades 120 of the first turbine stage 112, viewed in the direction of flow of the working medium 113, are subjected to the greatest thermal stress in addition to the heat shield bricks lining the annular combustion chamber 106. In order to withstand the temperatures prevailing there, they are cooled by means of a coolant.
  • the turbine blade 120, 130 is still air-cooled and has film cooling holes 13 which are connected to the casting mold 16 (FIG. Fig. 2-6 ) in the cast and / or directionally solidified turbine blade 120, 130.
  • the vane 130 has a guide vane foot (not shown here) facing the inner housing 138 of the turbine 108 and a vane head opposite the vane foot.
  • the vane head faces the rotor 103 and fixed to a mounting ring 140 of the stator 143.
  • the FIG. 17 shows by way of example a combustion chamber 110 of a gas turbine 100.
  • the combustion chamber 110 is configured, for example, as a so-called annular combustion chamber, in which a plurality of burners 102 arranged around the turbine shaft 103 in the circumferential direction open into a common combustion chamber space.
  • the combustion chamber 110 is configured in its entirety as an annular structure, which is positioned around the turbine shaft 103 around.
  • the combustion chamber 110 is designed for a comparatively high temperature of the working medium M of about 1000 ° C to 1600 ° C.
  • the combustion chamber wall 153 is provided on its side facing the working medium M side with an inner lining formed from heat shield elements 155.
  • Each heat shield element 155 is equipped on the working medium side with a particularly heat-resistant protective layer or made of high-temperature-resistant material. Due to the high temperatures in the interior of the combustion chamber 110, a cooling system is additionally provided for the heat shield elements 155 or for their holding elements. Often the heat shield elements 155 have film cooling holes 13 or passages for fuel into the combustion chamber 110 created in the heat shield element 155 with the mold 16.
  • FIG. 18 shows a perspective view of a blade 120 or guide vane 130 of a turbomachine, which extends along a longitudinal axis 121.
  • the turbomachine may be a gas turbine of an aircraft or a power plant for power generation, a steam turbine or a compressor.
  • the blade 120, 130 has along the longitudinal axis 121 consecutively a fastening region 400, a blade platform 403 adjoining thereto and an airfoil 406. As a guide blade 130, the blade 130 may have at its blade tip 415 another platform (not shown).
  • a blade root 183 is formed, which serves for attachment of the blades 120, 130 to a shaft or a disc (not shown).
  • the blade root 183 is designed, for example, as a hammer head. Other designs as Christmas tree or Schwalbenschwanzfuß are possible.
  • the blade 120, 130 has a leading edge 409 and a trailing edge 412 for a medium flowing past the airfoil 406.
  • blade 120, 130 for example, solid metallic materials are used in all regions 400, 403, 406 of the blade 120, 130.
  • the blade 120, 130 can in this case be produced by a casting process by means of the casting mold 16, also by means of directed solidification, by a forging process, by a milling process or combinations thereof.
  • directionally solidified microstructures which means both single crystals that have no grain boundaries or at most small angle grain boundaries, and stem crystal structures that have probably longitudinal grain boundaries but no transverse grain boundaries. These second-mentioned crystalline structures are also known as directionally solidified structures. Such methods are known from U.S. Patent 6,024,792 and the EP 0 892 090 A1 known.
  • Refurbishment means that components 120, 130 may need to be deprotected after use (e.g., by sandblasting). This is followed by removal of the corrosion and / or oxidation layers or products. Optionally, even cracks in the component 120, 130 are repaired. This is followed by a re-coating of the component 120, 130 and a renewed use of the component 120, 130.
  • the blade 120, 130 may be hollow or solid.
  • the blade 120, 130 is hollow and may still film cooling holes 418 (indicated by dashed lines) on.
  • the blade 120, 130 for example, corresponding mostly metallic coatings (MCrAlX) and as protection against heat mostly a ceramic coating.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Turbine Rotor Nozzle Sealing (AREA)
EP08000499A 2004-12-27 2004-12-27 Procédé de fabrication d'un moule Not-in-force EP1920858B1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
DE502004009738T DE502004009738D1 (de) 2004-12-27 2004-12-27 Verfahren zur Herstellung einer Gussform

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
EP04030823A EP1674174B1 (fr) 2004-12-27 2004-12-27 Procédé de fabrication d'un moule de fonderie

Related Parent Applications (1)

Application Number Title Priority Date Filing Date
EP04030823A Division EP1674174B1 (fr) 2004-12-27 2004-12-27 Procédé de fabrication d'un moule de fonderie

Publications (2)

Publication Number Publication Date
EP1920858A1 true EP1920858A1 (fr) 2008-05-14
EP1920858B1 EP1920858B1 (fr) 2009-07-08

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Family Applications (2)

Application Number Title Priority Date Filing Date
EP04030823A Not-in-force EP1674174B1 (fr) 2004-12-27 2004-12-27 Procédé de fabrication d'un moule de fonderie
EP08000499A Not-in-force EP1920858B1 (fr) 2004-12-27 2004-12-27 Procédé de fabrication d'un moule

Family Applications Before (1)

Application Number Title Priority Date Filing Date
EP04030823A Not-in-force EP1674174B1 (fr) 2004-12-27 2004-12-27 Procédé de fabrication d'un moule de fonderie

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US (1) US20060162893A1 (fr)
EP (2) EP1674174B1 (fr)
DE (2) DE502004008983D1 (fr)

Families Citing this family (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20080005903A1 (en) * 2006-07-05 2008-01-10 United Technologies Corporation External datum system and film hole positioning using core locating holes
US20130280093A1 (en) 2012-04-24 2013-10-24 Mark F. Zelesky Gas turbine engine core providing exterior airfoil portion
WO2014113184A1 (fr) * 2013-01-18 2014-07-24 General Electric Company Procédé permettant de former des orifices de refroidissement coulés dans un composant d'aéronef
CN106232946B (zh) * 2014-02-25 2018-04-27 西门子公司 具有气流引导的像素化表面特征样式的涡轮机可磨耗层
WO2016133982A1 (fr) 2015-02-18 2016-08-25 Siemens Aktiengesellschaft Formation de passages de refroidissement dans des composants en superalliage de turbine à combustion recouverts d'isolant thermique
DE102019201085A1 (de) * 2019-01-29 2020-07-30 Siemens Aktiengesellschaft Herstellungsverfahren für ein Bauteil mit integrierten Kanälen

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0559251A1 (fr) * 1992-02-18 1993-09-08 General Motors Corporation Procédé pour la production des structure coulées, à paroi mince avec une résistance à chaud élevée
EP0892090A1 (fr) 1997-02-24 1999-01-20 Sulzer Innotec Ag Procédé de fabrication de structure smonocristallines
US6024792A (en) 1997-02-24 2000-02-15 Sulzer Innotec Ag Method for producing monocrystalline structures
US6329015B1 (en) 2000-05-23 2001-12-11 General Electric Company Method for forming shaped holes

Family Cites Families (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4487246A (en) * 1982-04-12 1984-12-11 Howmet Turbine Components Corporation System for locating cores in casting molds
US5810552A (en) * 1992-02-18 1998-09-22 Allison Engine Company, Inc. Single-cast, high-temperature, thin wall structures having a high thermal conductivity member connecting the walls and methods of making the same
US6637500B2 (en) * 2001-10-24 2003-10-28 United Technologies Corporation Cores for use in precision investment casting
GB0226559D0 (en) * 2002-11-14 2002-12-18 Rolls Royce Plc Investment moulding process and apparatus
US6929054B2 (en) * 2003-12-19 2005-08-16 United Technologies Corporation Investment casting cores

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0559251A1 (fr) * 1992-02-18 1993-09-08 General Motors Corporation Procédé pour la production des structure coulées, à paroi mince avec une résistance à chaud élevée
EP0892090A1 (fr) 1997-02-24 1999-01-20 Sulzer Innotec Ag Procédé de fabrication de structure smonocristallines
US6024792A (en) 1997-02-24 2000-02-15 Sulzer Innotec Ag Method for producing monocrystalline structures
US6329015B1 (en) 2000-05-23 2001-12-11 General Electric Company Method for forming shaped holes

Also Published As

Publication number Publication date
US20060162893A1 (en) 2006-07-27
EP1674174B1 (fr) 2009-02-11
EP1674174A1 (fr) 2006-06-28
DE502004009738D1 (de) 2009-08-20
DE502004008983D1 (de) 2009-03-26
EP1920858B1 (fr) 2009-07-08

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