EP1970142B1 - 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
- EP1970142B1 EP1970142B1 EP08150863A EP08150863A EP1970142B1 EP 1970142 B1 EP1970142 B1 EP 1970142B1 EP 08150863 A EP08150863 A EP 08150863A EP 08150863 A EP08150863 A EP 08150863A EP 1970142 B1 EP1970142 B1 EP 1970142B1
- Authority
- EP
- European Patent Office
- Prior art keywords
- wax
- ceramic core
- ceramic
- casting
- stiffening
- 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.)
- Not-in-force
Links
- 238000000034 method Methods 0.000 title claims description 24
- 238000005266 casting Methods 0.000 title claims description 22
- 239000000919 ceramic Substances 0.000 claims description 48
- 238000005495 investment casting Methods 0.000 claims description 13
- 239000000463 material Substances 0.000 claims description 9
- 239000002184 metal Substances 0.000 claims description 8
- 238000007598 dipping method Methods 0.000 claims description 4
- 238000002844 melting Methods 0.000 claims description 4
- 230000008018 melting Effects 0.000 claims description 3
- 239000012815 thermoplastic material Substances 0.000 claims description 3
- 239000002657 fibrous material Substances 0.000 claims 1
- 239000011162 core material Substances 0.000 description 25
- 238000001816 cooling Methods 0.000 description 9
- 238000004519 manufacturing process Methods 0.000 description 8
- 230000015572 biosynthetic process Effects 0.000 description 4
- 238000003825 pressing Methods 0.000 description 3
- 239000011230 binding agent Substances 0.000 description 2
- 239000011819 refractory material Substances 0.000 description 2
- 238000005507 spraying Methods 0.000 description 2
- 208000010392 Bone Fractures Diseases 0.000 description 1
- 206010017076 Fracture Diseases 0.000 description 1
- 230000005465 channeling Effects 0.000 description 1
- 230000001419 dependent effect Effects 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- 230000018109 developmental process Effects 0.000 description 1
- 239000000835 fiber Substances 0.000 description 1
- 238000007654 immersion Methods 0.000 description 1
- 229910001338 liquidmetal Inorganic materials 0.000 description 1
- 229910001092 metal group alloy Inorganic materials 0.000 description 1
- 239000007769 metal material Substances 0.000 description 1
- 238000000465 moulding Methods 0.000 description 1
- 238000007670 refining Methods 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 238000007711 solidification Methods 0.000 description 1
- 230000008023 solidification Effects 0.000 description 1
Images
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, in which formed between shell molds with a ceramic core provided therein for forming a cavity in the metallic component by injecting a wax mass and after the removal of 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 melting the wax mass and then poured with a molten metal and the mold and the ceramic 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 shape of refractory material is fired into a ceramic casting mold.
- the liquid metal is poured to produce the desired components. After the solidification of the metal become the ceramic Molds destroyed.
- the JP 2000 246392 A discloses a method of making wax models for investment casting.
- the method consists in determining particularly fracture-risk areas of the ceramic core and providing them with wax prior to the actual wax spraying in order to reinforce them and thus to prevent the breaking of the ceramic core during the actual spraying of the casting model.
- a ceramic core is coated with wax and then formed around the wax layer by repeated dipping in a ceramic binder and Besanden a ceramic mold, which is fired after the 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 in the casting process.
- the ceramic core pins positioned in the mold intended for the formation of the wax model are integrally formed on the ceramic core, which is arranged to form a cavity in the relevant component in the wax model mold.
- the stiffening layer is reinforced by fibers to increase the strength and rigidity of the stiffening layer.
- the stiffening layer may consist of wax or similar thermoplastic materials which melt together with the wax model material.
- cooling ducts with a small diameter and in different, for example conical 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 1 by the lost-wax process, the cavity 3 and also the through-channel 4 are produced.
- Fig. 2 are a ceramic core 5 for forming the cavity 3 and an 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 form of solid shell wax mold (not shown) with a is enclosed in this pressed wax mass 7.
- the brittle ceramic core pin 6 can easily break 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 can therefore during this process step not destroyed or damaged.
- the injected wax mass 7 and the fusible stiffening layer 8 are finally melted out and the ceramic casting mold is fired.
- the ceramic casting mold is then poured out with a planned for the turbine blade 1 molten metal alloy. 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 8 consists of a fiber-reinforced wax or other thermoplastic material that can be easily melted out during the lost wax from the ceramic 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.
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Molds, Cores, And Manufacturing Methods Thereof (AREA)
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 einem darin positionierten, zur Ausbildung eines Hohlraumes in dem metallischen Bauteil vorgesehen Keramikkern 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 der Wachsmasse gebrannt und anschließend mit einer Metallschmelze ausgegossen wird und die Gießform und der Keramikkern 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, in which formed between shell molds with a ceramic core provided therein for forming a cavity in the metallic component by injecting a wax mass and after the removal of 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 melting the wax mass and then poured with a molten metal and the mold and the ceramic 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 Anschluse 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 shape 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 the solidification of the metal become the ceramic Molds destroyed. With the method also referred to as investment casting complicated castings from different metallic materials, especially from so-called aviation turbine material existing turbine blades can be manufactured precisely and in high surface quality.
Die
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 Auf bringen bzw. Einpressen des Wachses für die anschließend. Erzeugung der Gießform leicht brechen kann. Es ist daher nicht möglich, Turbinenschaufeln mit Kühlkanälen sehr ge ringen 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 - characterized by the wax refining - investment casting process, since the very thin and also brittle ceramic core material for the channeling on Auf bring or pressing the wax for the subsequent. Generation of the mold can break easily. It is therefore not possible to produce turbine blades with cooling channels very ge wrestling 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 zu schaffen, 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 in 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 sind an den Keramikkern angeformt, der zur Ausbildung eines Hohlraums in dem betreffenden Bauteil in der Wachsmodellform angeordnet ist.The ceramic core pins positioned in the mold intended for the formation of the wax model are integrally formed on the ceramic core, which is arranged to form a cavity in the relevant component in the wax model mold.
Gemäß einem wichtigen Merkmal der Erfindung ist die Versteifungsschicht durch Fasern verstärkt, um die Festigkeit und Steifigkeit der Versteifungsschicht zu erhöhen.According to an important feature of the invention, the stiffening layer is reinforced by fibers to increase the strength and rigidity of the stiffening layer.
Die Versteifungsschicht kann aus Wachs oder ähnlichen thermoplastischen Werkstoffen bestehen, die zusammen mit dem Wachsmodellwerkstoff ausschmelzen.The stiffening layer may consist of wax or similar thermoplastic materials which melt together with the wax model material.
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 oder gekrümmter Form, ausgebildet werden.With the method according to the invention, in the production of turbine blades within the fine casting process, that is to say without additional processing steps, cooling ducts with a small diameter and in different, for example conical or curved, form are required to improve the efficiency of the engine.
Ein Ausführungsbeispiel des erfindungsgemäßen Verfahrens zum Feingießen von metallischen Bauteilen mit sehr dünnen Durchgangskanälen nach dem Wachsausschmelzverfahren wird anhand der Zeichnungen näher erläutert. Es zeigt:
- Fig. 1
- eine Schnittansicht eines Teils einer durch Feingießen erzeugten Turbinenschaufel mit in deren Schaufelfuß im Gießprozess integral aus- gebildeter Mikroturbinendüse und
- Fig. 2
- eine vergrößerte schematische Darstellung eines Keramikkerns zur Ausbildung eines Hohlraums und einer 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 a cavity and emanating from this Mikroturbinendüse in the turbine blade according to
Fig. 1
Gemäß der in
In
Die schmelzbare Versteifungsschicht 8 besteht aus einem durch Fasern verstärkten Wachs oder einem anderen thermoplastischen Material, das während des Wachsausschmelzens aus der keramischen Gießform leicht mit ausgeschmolzen werden kann.The fusible stiffening
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 (3)
- Method for precision casting of metallic components with very thin passage ducts (4), more particularly of turbine blades (1), by the lost-wax process, in which a wax pattern is produced by injecting wax material (7) between die shells with a ceramic core disposed therein for forming a cavity (3) in the metallic component and, after removal of the die shells, a ceramic casting mould is produced on the outer surface of the wax pattern in a dipping and sanding process which, upon melting out the wax material (7) is baked and into which molten metal is then poured, and the casting mould and the ceramic core (5) are subsequently destroyed and removed, witha) a ceramic core pin (6) being formed in a diameter corresponding to the diameter of the very thin passage duct (4),b) the ceramic core pin (6) being formed onto the ceramic core (5), with wax material (7) being sprayed around the ceramic core (5), andc) the ceramic core pin (6) being coated and stabilized with a meltable stiffening coat (8) prior to injecting the wax material (7), this stiffening coat (8) being melted out together with the wax material (7),
characterized in that the stiffening coat (8) is reinforced by fiber material. - Method in accordance with Claim 1, characterized in that the stiffening coat (8) consists of wax or another thermoplastic material.
- Method in accordance with Claim 1, characterized in that the ceramic core pin (6) is conical or curved according to the shape of the passage ducts (4).
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 EP1970142A1 (en) | 2008-09-17 |
| EP1970142B1 true 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) |
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| DE102013016868A1 (en) * | 2013-10-11 | 2015-04-16 | Flc Flowcastings Gmbh | Investment casting of hollow components |
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| DE10236339B3 (en) | 2002-08-08 | 2004-02-19 | Doncasters Precision Castings-Bochum Gmbh | Method for manufacturing turbine blades with cooling ducts involves making ceramic core with positioning pins embedded in free end to protrude into surrounding moulding shell for removal during mechanical finishing of hardened blades |
| DE10346366A1 (en) * | 2003-09-29 | 2005-04-28 | Rolls Royce Deutschland | Turbine blade for an aircraft engine and casting mold for the production thereof |
| US7036556B2 (en) * | 2004-02-27 | 2006-05-02 | Oroflex Pin Development Llc | Investment casting pins |
| US7216689B2 (en) * | 2004-06-14 | 2007-05-15 | United Technologies Corporation | Investment casting |
| US7093645B2 (en) * | 2004-12-20 | 2006-08-22 | Howmet Research Corporation | Ceramic casting core and method |
-
2007
- 2007-03-09 DE DE102007012321A patent/DE102007012321A1/en not_active Withdrawn
-
2008
- 2008-01-31 EP EP08150863A patent/EP1970142B1/en not_active Not-in-force
- 2008-03-07 US US12/073,622 patent/US8096343B2/en not_active Expired - Fee Related
Also Published As
| Publication number | Publication date |
|---|---|
| EP1970142A1 (en) | 2008-09-17 |
| US8096343B2 (en) | 2012-01-17 |
| US20080216983A1 (en) | 2008-09-11 |
| DE102007012321A1 (en) | 2008-09-11 |
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