EP1970142A1 - Method for fine casting of metallic parts with narrow channels - Google Patents
Method for fine casting of metallic parts with narrow channels Download PDFInfo
- Publication number
- EP1970142A1 EP1970142A1 EP08150863A EP08150863A EP1970142A1 EP 1970142 A1 EP1970142 A1 EP 1970142A1 EP 08150863 A EP08150863 A EP 08150863A EP 08150863 A EP08150863 A EP 08150863A EP 1970142 A1 EP1970142 A1 EP 1970142A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- wax
- mold
- ceramic
- casting
- ceramic core
- 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
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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 investment casting of metal components with very thin through channels by the lost wax process, in particular of turbine blades, formed in between the mold shells with ceramic core positioned therein by injecting a wax mass, a wax model and after removing the shell molds on the outer surface of the wax model in a dipping and Besandungslui a ceramic mold is produced, which is fired after the melting of the wax and then poured with a molten metal and the mold and the core then destroyed and removed.
- a non-meltable mold (wax mold, mold shell) is first produced from a master model in which a wax model consisting of a fusible material, in particular a special wax, is produced in a casting process.
- the wax models provided with a casting system are assembled into model screws and then coated with a refractory material in a multiple immersion and Besandungslui.
- the wax model is then melted out and then the remaining mold of refractory material is fired into a ceramic casting mold.
- the liquid metal is poured to produce the desired components. After solidification of the metal, the ceramic molds are destroyed.
- a ceramic core is overmolded with wax and then formed around the wax layer by repeated dipping in a ceramic binder and dressing a ceramic casting mold which is fired after removal of the wax.
- the free space left by the melting of the wax between the core and the shell mold is poured out with molten metal to form the turbine blade. Movements of the core during pouring can be prevented by metallic positioning aids mounted in the ceramic core. After pouring and solidifying the metal, the ceramic core and the ceramic casting shell are destroyed and removed. Subsequently, the casting is machined and the positioning aids are removed again.
- cooling channels profilings are formed on the ceramic core.
- the invention has for its object to provide a precision casting on the basis of lost wax for the production of turbine blades with through channels, which also allows the production of very thin through-channels within the casting process.
- the ceramic core pins positioned in the mold provided for the formation of the wax model may be molded to a ceramic core arranged to form a cavity in the respective component in the wax pattern mold.
- the stiffening layer can be made of wax or similar thermoplastic materials which melt together with the wax model material.
- the stiffening layer is reinforced by fibers to increase the strength and rigidity of the stiffening layer.
- cooling ducts of small diameter and in different, for example conical and / or curved, form are required to improve the efficiency of the engine.
- Turbine vane 1 which is only partially illustrated, starts from a cavity 3 formed in the blade root 2 as a passage channel 4 with a very small diameter acting as a microturbine nozzle for the passage of cooling air. Together with the investment casting of the turbine blade by the lost wax process, the cavity 3 and also the through-channel 4 are produced.
- Fig. 2 the ceramic core 5 for forming the cavity 3 and the integrally formed thin ceramic core pin 6 for forming the equally thin through-channel 4 is shown, which - according to the lost wax process - for the production of the ceramic mold first in an existing solid shell molded wax mold (not shown) with a is enclosed in this pressed wax mass 7.
- the brittle ceramic core pin 6 can break easily due to its small diameter when applying or injecting the wax mass 7, this is coated with a fusible stiffening layer 8 before pressing the wax mass 7 and therefore can not be destroyed or damaged during this process step.
- the injected wax mass 7 and the fusible stiffening layer 8 are melted and the ceramic casting mold is fired.
- the ceramic casting mold is then poured out with a molten metal alloy intended for the turbine blade. In the subsequent process step, the ceramic casting mold and the ceramic core 5 and the ceramic core pin 6 are destroyed and removed.
- the fusible stiffening layer can also be made of wax or a fiber-reinforced wax or other thermoplastic material that can be easily melted out during the lost-wax casting from the ceramic casting mold.
- the invention is not limited to the previously explained application. It can always be used in casting by the lost wax casting turbine blades or other components where thin channels can no longer be produced during casting with a correspondingly thin ceramic core and otherwise separate production of thin through-channels is too expensive, for example, in a support structure in the area of the guide vanes of a turbine stage to form a very narrow pre-swirl nozzle or to form very thin channels in the turbine blade tips.
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Molds, Cores, And Manufacturing Methods Thereof (AREA)
Abstract
Description
Die Erfindung betrifft ein Verfahren zum Feingießen von metallischen Bauteilen mit sehr dünnen Durchgangskanälen nach dem Wachsausschmelzverfahren, insbesondere von Turbinenschaufeln, bei dem zwischen Formschalen mit darin positioniertem keramischem Kern durch Einpressen einer Wachsmasse ein Wachsmodell geformt und nach dem Entfernen der Formschalen an der Außenfläche des Wachsmodells in einem Tauch- und Besandungsprozess eine keramische Gießform erzeugt wird, die nach dem Ausschmelzen des Wachses gebrannt und anschließend mit einer Metallschmelze ausgegossen wird und die Gießform und der Kern anschließend zerstört und entfernt werden.The invention relates to a method for investment casting of metal components with very thin through channels by the lost wax process, in particular of turbine blades, formed in between the mold shells with ceramic core positioned therein by injecting a wax mass, a wax model and after removing the shell molds on the outer surface of the wax model in a dipping and Besandungsprozess a ceramic mold is produced, which is fired after the melting of the wax and then poured with a molten metal and the mold and the core then destroyed and removed.
Es ist bekannt, mit Kühlluftbohrungen ausgebildete Turbinenschaufeln nach dem Wachsausschmelzverfahren zu fertigen. Beim Wachsausschmelzverfahren wird aus einem Urmodell zunächst ein nicht schmelzbares Formwerkzeug (Wachsmodellform, Formschalen) hergestellt, in dem in einem Gießprozess ein aus einem schmelzbaren Material, insbesondere einem Spezialwachs, bestehendes Wachsmodell erzeugt wird. Im nächsten Schritt werden die mit einem Gießsystem versehenen Wachsmodelle zu Modelltrauben zusammengefügt und danach in einem mehrfachen Tauch- und Besandungsprozess mit einem feuerfesten Material ummantelt. Das Wachsmodell wird anschließend ausgeschmolzen und im Anschluss wird die zurückbleibende Form aus feuerfestem Material zu einer keramischen Gießform gebrannt. In den so erzeugten keramischen Formen wird zur Herstellung der gewünschten Bauteile das flüssige Metall vergossen. Nach dem Erstarren des Metalls werden die keramischen Gießformen zerstört. Mit dem auch als Feingießen bezeichneten Verfahren können komplizierte Gussteile aus unterschiedlichen metallischen Werkstoffen, insbesondere auch aus sogenannten Luftfahrtwerkstoffen bestehende Turbinenschaufeln, präzise und in hoher Oberflächenqualität gefertigt werden.It is known to manufacture turbine blades formed with cooling-air bores by the lost-wax method. In the lost wax process, a non-meltable mold (wax mold, mold shell) is first produced from a master model in which a wax model consisting of a fusible material, in particular a special wax, is produced in a casting process. In the next step, the wax models provided with a casting system are assembled into model screws and then coated with a refractory material in a multiple immersion and Besandungsprozess. The wax model is then melted out and then the remaining mold of refractory material is fired into a ceramic casting mold. In the ceramic molds thus produced, the liquid metal is poured to produce the desired components. After solidification of the metal, the ceramic molds are destroyed. With the as well as investment casting Designated method complicated castings made of different metallic materials, especially from so-called aerospace turbine blades, can be manufactured precisely and in high surface quality.
Bei einem beispielsweise aus der
Zur Einschränkung des Kühlluftverbrauchs und zur damit verbundenen Erhöhung der Effizienz des Gasturbinentriebwerks ist es erforderlich, die Kühlluftkanäle mit einem möglichst kleinen Durchmesser auszuführen.To restrict the cooling air consumption and the associated increase in the efficiency of the gas turbine engine, it is necessary to carry out the cooling air ducts with the smallest possible diameter.
Die Ausbildung von solchen dünnen Durchgangsbohrungen in einer Turbinenschaufel ist mit dem oben erwähnten - durch das Wachsaufschmelzen charakterisierten - Feingießverfahren nicht realisierbar, da das sehr dünne und zudem spröde keramische Kernmaterial für die Kanalbildung beim Aufbringen bzw. Einpressen des Wachses für die anschließende Erzeugung der Gießform leicht brechen kann. Es ist daher nicht möglich, Turbinenschaufeln mit Kühlkanälen sehr geringen Durchmessers durch Feingießen herzustellen. Die Turbinenschaufeln können somit nur mit dem für den Wirkungsgrad des Triebwerks nachteiligen Design (großer Kühlkanaldurchmesser) kostengünstig durch Feingießen gefertigt werden oder die vorteilhaften dünnen Bohrungen müssen in einem separaten Verfahrensschritt und damit verbundenen höheren Kosten nachträglich in die Schaufel eingebracht werden.The formation of such thin through-holes in a turbine blade is not feasible with the above-mentioned fine casting process characterized by the wax-up, since the very thin and also brittle ceramic core material for the channeling during application or pressing the wax for the subsequent generation of the mold can easily break. It is therefore not possible to produce turbine blades with cooling channels of very small diameter by investment casting. The turbine blades can thus be manufactured inexpensively by investment casting only with the disadvantageous for the efficiency of the engine design (large cooling channel diameter) or the advantageous thin holes must be subsequently introduced into the blade in a separate process step and associated higher costs.
Der Erfindung liegt die Aufgabe zugrunde, ein Feingießverfahren auf der Basis des Wachsausschmelzens zur Herstellung von Turbinenschaufeln mit Durchgangskanälen anzugeben, das auch die Fertigung sehr dünner Durchgangskanäle im Rahmen des Gießprozesses gestattet.The invention has for its object to provide a precision casting on the basis of lost wax for the production of turbine blades with through channels, which also allows the production of very thin through-channels within the casting process.
Erfindungsgemäß wird die Aufgabe mit einem Verfahren gemäß den Merkmalen des Patentanspruchs 1 gelöst. Vorteilhafte Weiterbildungen der Erfindung ergeben sich aus den Unteransprüchen.According to the invention the object is achieved by a method according to the features of
Beim Feingießen von metallischen Bauteilen mit sehr dünnen Durchgangskanälen nach dem Wachsausschmelzverfahren, und zwar insbesondere bei der Herstellung von Turbinenschaufeln mit Durchgangskanälen für Kühlluft im Schaufelfuß, in der Plattform oder in der Wandung des als Hohlkörper ausgebildeten Schaufelblatts, werden die zur Ausformung der Durchgangskanäle vorgesehenen und entsprechend dünn dimensionierten Keramikkernstifte - vor dem Einpressen der Wachsmasse zur Gestaltung des Wachsmodells für die nachfolgende Ausbildung der keramischen Gießform zum Gießen des Bauteils - mit einer niedrigschmelzenden Versteifungsschicht, die nach dem Anformen der Gießform zusammen mit der Wachsmasse des Wachsmodells wieder ausgeschmolzen wird, ummantelt und stabilisiert.When investment casting of metal components with very thin through channels by the lost wax process, in particular in the production of turbine blades with passage channels for cooling air in the blade root, in the platform or in the wall of the formed as a hollow body blade, which are provided for forming the through-channels and accordingly thinly dimensioned ceramic core pins - prior to pressing the wax mass to the design of the wax model for the subsequent formation of the ceramic mold for casting the component - with a low-melting stiffening layer, after molding of the mold is melted out again, coated and stabilized together with the wax mass of the wax model.
Die in der für die Ausbildung des Wachsmodells vorgesehenen Form positionierten Keramikkernstifte können an einen Keramikkern angeformt sein, der zur Ausbildung eines Hohlraums in dem betreffenden Bauteil in der Wachsmodellform angeordnet ist.The ceramic core pins positioned in the mold provided for the formation of the wax model may be molded to a ceramic core arranged to form a cavity in the respective component in the wax pattern mold.
Die Versteifungsschicht kann aus Wachs oder ähnlichen thermoplastischen Werkstoffen bestehen, die zusammen mit dem Wachsmodellwerkstoff ausschmelzen.The stiffening layer can be made of wax or similar thermoplastic materials which melt together with the wax model material.
Gemäß einem weiteren wichtigen Merkmal der Erfindung ist die Versteifungsschicht durch Fasern verstärkt, um die Festigkeit und Steifigkeit der Versteifungsschicht zu erhöhen.According to another important feature of the invention, the stiffening layer is reinforced by fibers to increase the strength and rigidity of the stiffening layer.
Mit dem erfindungsgemäßen Verfahren können bei der Herstellung von Turbinenschaufeln im Rahmen des Feingießprozesses, das heißt ohne zusätzliche Bearbeitungsschritte, zur Verbesserung der Effizienz des Triebwerks erforderliche Kühlkanäle mit geringem Durchmesser und in unterschiedlicher, beispielsweise konischer und/oder gekrümmter Form, ausgebildet werden.With the method according to the invention, in the production of turbine blades within the fine casting process, ie without additional processing steps, cooling ducts of small diameter and in different, for example conical and / or curved, form are required to improve the efficiency of the engine.
Ein Ausführungsbeispiel der Erfindung wird anhand der Zeichnung, in der
- Fig. 1
- eine Schnittansicht eines Teils einer durch Feingießen erzeugten Turbinenschaufel mit in deren Schaufelfuß im Gießprozess integral ausgebildeter Mikroturbinendüse; und
- Fig. 2
- eine vergrößerte schematische Darstellung eines Keramikkerns zur Ausbildung des Hohlraums und der von diesem ausgehenden Mikroturbinendüse in der Turbinenschaufel nach
Fig. 1
- Fig. 1
- a sectional view of a portion of a turbine blade produced by investment casting with integrally formed in their blade root in the casting process Mikroturbinendüse; and
- Fig. 2
- an enlarged schematic representation of a ceramic core for forming the cavity and the outgoing of this microturbine nozzle in the turbine blade
Fig. 1
Gemäß der in
In
Die schmelzbare Versteifungsschicht kann ebenfalls aus Wachs oder aus einem durch Fasern verstärkten Wachs oder einem anderen thermoplastischen Material bestehen, das während des Wachsausschmelzens aus der keramischen Gießform leicht mit ausgeschmolzen werden kann.The fusible stiffening layer can also be made of wax or a fiber-reinforced wax or other thermoplastic material that can be easily melted out during the lost-wax casting from the ceramic casting mold.
Die Erfindung ist nicht auf den zuvor erläuterten Anwendungsfall beschränkt. Sie kann bei nach dem Wachsausschmelzverfahren gegossenen Turbinenschaufeln oder auch anderen Bauteilen immer dort angewendet werden, wo dünne Kanäle beim Gießen mit einem entsprechend dünn auszuführenden keramischen Kern nicht mehr hergestellt werden können und eine anderweitige separate Herstellung der dünnen Durchgangskanäle zu kostenaufwendig ist, beispielsweise bei einer Haltestruktur im Bereich der Leitschaufeln einer Turbinenstufe zur Ausbildung einer sehr schmalen Vorverwirbelungsdüse (pre-swirl nozzle) oder zur Ausbildung sehr dünner Kanäle in den Turbinenschaufelspitzen.The invention is not limited to the previously explained application. It can always be used in casting by the lost wax casting turbine blades or other components where thin channels can no longer be produced during casting with a correspondingly thin ceramic core and otherwise separate production of thin through-channels is too expensive, for example, in a support structure in the area of the guide vanes of a turbine stage to form a very narrow pre-swirl nozzle or to form very thin channels in the turbine blade tips.
- 11
- Turbinenschaufelturbine blade
- 22
- Schaufelfußblade
- 33
- Hohlraumcavity
- 44
- Durchgangskanal (Vorverwirbelungsdüse)Through-channel (pre-swirl nozzle)
- 55
- Keramikkernceramic core
- 66
- KeramikkernstiftCeramic core pin
- 77
- Wachsmassewax material
- 88th
- Versteifungsschichtstiffening layer
Claims (5)
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
DE102007012321A DE102007012321A1 (en) | 2007-03-09 | 2007-03-09 | Process for investment casting of metallic components with thin through-channels |
Publications (2)
Publication Number | Publication Date |
---|---|
EP1970142A1 true EP1970142A1 (en) | 2008-09-17 |
EP1970142B1 EP1970142B1 (en) | 2011-09-28 |
Family
ID=39325914
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP08150863A Not-in-force EP1970142B1 (en) | 2007-03-09 | 2008-01-31 | Method for fine casting of metallic parts with narrow channels |
Country Status (3)
Country | Link |
---|---|
US (1) | US8096343B2 (en) |
EP (1) | EP1970142B1 (en) |
DE (1) | DE102007012321A1 (en) |
Cited By (2)
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CN103706760A (en) * | 2014-01-06 | 2014-04-09 | 安徽厚林精密金属科技有限公司 | Method for precisely casting top cover of mincing machine |
CN113441688A (en) * | 2021-06-30 | 2021-09-28 | 共享装备股份有限公司 | Chaplet and using method |
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US9315663B2 (en) | 2008-09-26 | 2016-04-19 | Mikro Systems, Inc. | Systems, devices, and/or methods for manufacturing castings |
WO2011019672A2 (en) * | 2009-08-09 | 2011-02-17 | Rolls-Royce Corporation | Support for a fired article |
US8813824B2 (en) | 2011-12-06 | 2014-08-26 | Mikro Systems, Inc. | Systems, devices, and/or methods for producing holes |
CN103056302A (en) * | 2011-12-13 | 2013-04-24 | 丹阳市精密合金厂有限公司 | Ceramic core for molding aeroengine case type annular casting hollow support plate |
CN103056303A (en) * | 2011-12-13 | 2013-04-24 | 丹阳市精密合金厂有限公司 | Ceramic core for supporting plate forming |
CN102601306A (en) * | 2012-03-31 | 2012-07-25 | 四川德力铁道科技有限公司 | Mould material module hot water dewaxing method for wax mould precision casting process |
DE102013016868A1 (en) * | 2013-10-11 | 2015-04-16 | Flc Flowcastings Gmbh | Investment casting of hollow components |
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CN107790644A (en) * | 2017-11-09 | 2018-03-13 | 东方电气集团东方汽轮机有限公司 | A kind of method for preventing Hollow Blade Wax patterns from deforming |
US11179769B2 (en) | 2019-02-08 | 2021-11-23 | Raytheon Technologies Corporation | Investment casting pin and method of using same |
CN112077261B (en) * | 2019-06-13 | 2021-10-08 | 中国航发商用航空发动机有限责任公司 | Preparation process of porous casting |
US11642720B2 (en) | 2019-10-16 | 2023-05-09 | Raytheon Technologies Corporation | Integral core bumpers |
US11326470B2 (en) * | 2019-12-20 | 2022-05-10 | General Electric Company | Ceramic matrix composite component including counterflow channels and method of producing |
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Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN103706760A (en) * | 2014-01-06 | 2014-04-09 | 安徽厚林精密金属科技有限公司 | Method for precisely casting top cover of mincing machine |
CN103706760B (en) * | 2014-01-06 | 2016-06-22 | 安徽厚林精密金属科技有限公司 | A kind of casting method of meat grinder top cover |
CN113441688A (en) * | 2021-06-30 | 2021-09-28 | 共享装备股份有限公司 | Chaplet and using method |
CN113441688B (en) * | 2021-06-30 | 2022-07-08 | 共享装备股份有限公司 | Chaplet and using method |
Also Published As
Publication number | Publication date |
---|---|
EP1970142B1 (en) | 2011-09-28 |
US8096343B2 (en) | 2012-01-17 |
US20080216983A1 (en) | 2008-09-11 |
DE102007012321A1 (en) | 2008-09-11 |
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