EP2155418A1 - Procédé de fabrication d'une pièce coulée, moule de coulée et pièce coulée fabriquée avec ce dernier - Google Patents

Procédé de fabrication d'une pièce coulée, moule de coulée et pièce coulée fabriquée avec ce dernier

Info

Publication number
EP2155418A1
EP2155418A1 EP08758018A EP08758018A EP2155418A1 EP 2155418 A1 EP2155418 A1 EP 2155418A1 EP 08758018 A EP08758018 A EP 08758018A EP 08758018 A EP08758018 A EP 08758018A EP 2155418 A1 EP2155418 A1 EP 2155418A1
Authority
EP
European Patent Office
Prior art keywords
casting
mold
metallic layer
metal
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.)
Withdrawn
Application number
EP08758018A
Other languages
German (de)
English (en)
Inventor
Roland Huttner
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.)
MTU Aero Engines AG
Original Assignee
MTU Aero Engines GmbH
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 MTU Aero Engines GmbH filed Critical MTU Aero Engines GmbH
Publication of EP2155418A1 publication Critical patent/EP2155418A1/fr
Withdrawn legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D19/00—Casting in, on, or around objects which form part of the product
    • B22D19/0072—Casting in, on, or around objects which form part of the product for making objects with integrated channels
    • 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
    • B22C9/105—Salt cores
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/13—Hollow or container type article [e.g., tube, vase, etc.]
    • Y10T428/1352—Polymer or resin containing [i.e., natural or synthetic]
    • Y10T428/1355—Elemental metal containing [e.g., substrate, foil, film, coating, etc.]

Definitions

  • the present invention relates to a method for producing a cast part from metal, a metal alloy or from plastic with at least one complex internal structure, in particular with at least one cavity, by means of at least one casting mold.
  • the invention further relates to a casting mold for producing a casting made of metal, a metal alloy or plastic with at least one complex internal structure, in particular with at least one cavity, and a casting.
  • An inventive method for producing a casting of metal, a metal alloy or plastic with at least one complex internal structure, in particular with at least one cavity comprises at least one mold and the following steps: a) providing at least one core element, wherein the core element, the complex Interior structure imitates circumferentially and has on its outer periphery a metallic layer; c) casting over the positive mold with a shell to form a second casting or negative mold of the casting and removing the positive mold; d) filling casting material into the second casting or negative mold and cooling the casting material; and e) removing the shell and removing the casting.
  • the step: "b) forming a first casting or negative mold for producing a cast-replicating positive mold having one or more cast-in core elements" is performed.
  • the core element may consist of a hollow metal core according to one embodiment.
  • the hollow metal core can in turn be produced by means of an additive manufacturing process, in particular a rapid prototyping process.
  • the core element consists of a basic shape of a fusible carrier material, wherein the carrier material is coated on its outer surface with a metallic layer.
  • the basic shape can in turn be produced by means of a generative manufacturing process, in particular a rapid prototyping process.
  • the on the outer surface of the basic form or the Outer surface of the substrate formed metallic layer can be applied electrochemically.
  • a metal coating method can be used, which is particularly suitable for metal deposition on plastic parts.
  • the basic shape may be hollow or solid. Instead of a massive design of the basic shape and carrier elements can be arranged in a hollow basic shape.
  • the core element consists of a basic form of an ausschmelzbaren carrier material
  • this is made from the finished casting.
  • materials for the basic form or the carrier material basically all materials can be used which can be used on the one hand in a generative manufacturing process, in particular a rapid prototyping process and are melted out.
  • the metallic layer consists of a metal or a metal alloy, wherein the metal or the metal alloy have a higher melting point than the casting material. This ensures that the metallic layer remains in the casting and the protective function over the complex internal structure is maintained.
  • the casting material may be made of aluminum and the metallic layer of copper or a copper alloy.
  • the first cast or negative mold is made of plastic or silicone. This makes it possible to generate the first cast or negative mold relatively quickly.
  • the positive mold consists of a readily meltable metal, in particular wax.
  • wax By pouring the first cast or negative mold with z. B. wax results in a detailed replica of the casting to be cast.
  • the production of a so-called wax facilitates its subsequent removal from the second cast or negative mold.
  • the shell formed in method step c) consists of ceramic. This choice of material is advantageous because on the one hand ceramic allows precise casting of the positive mold and on the other hand can be easily removed again from the finished casting again.
  • the thickness of the core element or the thickness of the metallic layers is 0.5 to 5 mm.
  • a casting mold according to the invention for producing a casting made of metal, a metal alloy or plastic with at least one complex internal structure, in particular with at least one cavity has in the region of the complex internal structure a metallic layer for delimitation from the internal structure.
  • the metallic layer may consist of a metal or a metal alloy, wherein the metal or the metal alloy have a higher melting point than the casting material.
  • copper or a copper alloy may be used as a cast material for aluminum.
  • the metallic layer consists of a hollow metal core, wherein the hollow metal core is produced by means of a generative manufacturing process, in particular a rapid prototyping process.
  • the metallic layer by means of a core element consisting of a basic form of a fusible carrier material, which is coated on its outer surface with the metallic layer, can be produced.
  • the basic shape can also be produced by means of a generative production method, in particular a rapid prototyping method.
  • the metallic layer can be applied to the basic form electrochemically.
  • the methods known by the term "metal coating" have been found to be advantageous
  • the basic shape may be hollow or solid, and support elements formed in a hollow basic shape are also conceivable.
  • the thickness of the metallic layers is 0.5 to 5 mm.
  • the basic shape of the core element is produced by means of a generative manufacturing process, in particular a rapid prototyping process.
  • a generative manufacturing process in particular a rapid prototyping process.
  • all materials which can be processed and melted out by means of a generative production method, in particular a rapid prototyping method can be used as materials for the basic form or the carrier material.
  • a casting according to the invention is manufactured according to a method with the features described above or with a casting mold according to the features described above.
  • the casting may be part of an aircraft engine or a gas turbine.
  • FIG. 1 is a schematic representation of two core elements used according to the method of the invention.
  • FIG. 2 shows a schematic sectional view through a partial region of a core element used according to the method according to the invention
  • FIG. 3 shows a schematic, partially sectioned illustration of a first casting or negative mold with inserted core elements used according to the method according to the invention
  • FIG. 4 shows a schematic representation of a positive mold with inserted core elements used according to the method according to the invention
  • Figure 5 is a schematic representation of a casting produced according to the inventive method with inserted core elements.
  • Figure 6 is a schematic representation of a casting produced according to the inventive method.
  • FIG. 1 shows a schematic representation of two core elements 12, 14 used in accordance with the method presented.
  • the core elements 12, 14 form a complex inner structure 18 (see FIG. 6) circumferentially and have a metallic layer 22 on their respective outer circumference 20.
  • the complex internal structures 18 simulated by the core elements 12, 14 are cooling channels of a casting 10, namely a protective gas nozzle (see FIG. 6).
  • the core elements 12, 14 each consist of a basic shape 28 of a fusible carrier material 30, wherein the carrier material 30 is coated on its outer surface with the metallic layer 22.
  • FIG. 2 shows a schematic sectional view through a partial region of the core elements 12, 14.
  • the core elements 12, 14 are solid.
  • the cavity formed by the carrier material 30 is filled by a support material 36.
  • Both the carrier material 30 and the support material 36 must be meltable.
  • these are materials that can be processed by means of a rapid prototyping process. Plastics have proved to be particularly suitable here.
  • the carrier material 30 and the support material 36 consist of the same material. However, different materials can be used.
  • the core elements 12, 14 are used in a method step a) in the method for producing a cast part from metal, a metal alloy or from plastic with at least one complex inner structure 18, in particular with at least one cavity using a casting mold.
  • a first casting or negative mold 26 for producing a positive mold 24 simulating the casting 10 takes place with the two cast-in core elements 12, 14.
  • the formation of the first casting or negative mold 26 is shown schematically in FIG. partially cut representation shown. It can be seen that the core elements 12, 14 are inserted into the first cast or negative mold 26. A cavity 16 of the first casting or negative mold 26 is filled with a fusible material, in particular wax, so that it comes to a pouring of the core elements 12, 14 in said positive mold 24.
  • the positive mold 24 is shown in FIG. In addition, it is indicated in FIG. 4 that a sprue 32 and a riser 34 are attached to the positive mold 24.
  • FIG. 5 shows a schematic representation of a cast part 10 produced in this way, with core elements 12, 14 still inserted.
  • the protruding cores are subsequently separated off, the basic shape 28 or the carrier material 30 and the support material 36 are melted out so that ultimately the one shown schematically in FIG finished casting 10 remains.
  • the rapid prototyping processes used to produce the core elements 12, 14 can be, for example, the process families of stereolithography, laser sintering, layer (laminate) processes, extrusion processes or 3D printing.

Landscapes

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

Abstract

L'invention concerne un procédé de fabrication d'une pièce coulée (10) en métal, en alliage métallique ou en matière synthétique, qui présente au moins une structure intérieure complexe (18), en particulier au moins un espace creux, au moyen d'au moins un moule de coulée. Le procédé comprend les étapes suivantes : a) préparation d'au moins un élément de noyau (12, 14), l'élément de noyau (12, 14) reproduisant initialement la structure intérieure complexe (18) et présentant à sa périphérie extérieure (20) une couche métallique (22), b) formation d'un premier moule de coulée ou négatif pour former un moule positif qui reproduit la pièce moulée (10) et dans lequel un ou plusieurs éléments de noyau (12, 14) sont coulés, c) coulée autour du moule positif d'une enveloppe pour former un deuxième moule de coulée ou moule négatif de la pièce coulée (10) et enlèvement du moule positif, d) remplissage du moule de coulée ou négatif avec le matériau de coulée et refroidissement du matériau de coulée et e) séparation de l'enveloppe et enlèvement de la pièce coulée (10). L'invention concerne en outre un moule de coulée destiné à fabriquer une pièce moulée en métal, en alliage de métal ou en matière synthétique et qui présente au moins une structure intérieure complexe (18), en particulier au moins un espace creux, le moule de coulée (16) présentant dans la zone occupée par la structure intérieure complexe (18) une couche métallique (22) qui délimite la structure intérieure (18).
EP08758018A 2007-05-16 2008-05-02 Procédé de fabrication d'une pièce coulée, moule de coulée et pièce coulée fabriquée avec ce dernier Withdrawn EP2155418A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102007023152A DE102007023152A1 (de) 2007-05-16 2007-05-16 Verfahren zur Herstellung eines Gussteils, Gussform und damit hergestelltes Gussteil
PCT/DE2008/000757 WO2008138302A1 (fr) 2007-05-16 2008-05-02 Procédé de fabrication d'une pièce coulée, moule de coulée et pièce coulée fabriquée avec ce dernier

Publications (1)

Publication Number Publication Date
EP2155418A1 true EP2155418A1 (fr) 2010-02-24

Family

ID=39721966

Family Applications (1)

Application Number Title Priority Date Filing Date
EP08758018A Withdrawn EP2155418A1 (fr) 2007-05-16 2008-05-02 Procédé de fabrication d'une pièce coulée, moule de coulée et pièce coulée fabriquée avec ce dernier

Country Status (4)

Country Link
US (1) US20100304064A1 (fr)
EP (1) EP2155418A1 (fr)
DE (1) DE102007023152A1 (fr)
WO (1) WO2008138302A1 (fr)

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CN112399908A (zh) * 2018-06-25 2021-02-23 考里安公司 形成微结构阵列模具的混合方法、制作微结构阵列的方法以及使用方法

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US20130333855A1 (en) * 2010-12-07 2013-12-19 Gary B. Merrill Investment casting utilizing flexible wax pattern tool for supporting a ceramic core along its length during wax injection
US20130026338A1 (en) * 2011-07-28 2013-01-31 Lea Kennard Castle Rapid casting article manufacturing
US8561668B2 (en) * 2011-07-28 2013-10-22 United Technologies Corporation Rapid manufacturing method
FR2981867B1 (fr) * 2011-10-26 2016-02-12 Snecma Procede de fabrication d'une piece metallique pour turboreacteur d'aeronefs
DE102012203506A1 (de) * 2012-03-06 2013-09-12 Krones Ag Streckblasmaschine mit Rapid Prototyping Bauteilen
US9079803B2 (en) * 2012-04-05 2015-07-14 United Technologies Corporation Additive manufacturing hybrid core
CN103212695A (zh) * 2013-04-16 2013-07-24 华南理工大学 基于金属3d打印的新型异种材料复合铸造方法
WO2015011233A1 (fr) * 2013-07-24 2015-01-29 Emil Müller GmbH Noyaux de sel et procédé de fabrication additive pour réaliser des noyaux de sel
WO2015011232A1 (fr) * 2013-07-24 2015-01-29 Emil Müller GmbH Noyaux de sel et procédés de fabrication additive pour réaliser des noyaux de sel
WO2015014711A1 (fr) * 2013-07-24 2015-02-05 Emil Müller GmbH Noyaux de sel et procédés de fabrication additive pour réaliser des noyaux de sel
CN103587015B (zh) * 2013-11-21 2016-01-20 四川省祥业机械铸造有限公司 一种树脂模具及制模工艺
US10099284B2 (en) * 2015-12-17 2018-10-16 General Electric Company Method and assembly for forming components having a catalyzed internal passage defined therein
US10099276B2 (en) 2015-12-17 2018-10-16 General Electric Company Method and assembly for forming components having an internal passage defined therein
US9987677B2 (en) 2015-12-17 2018-06-05 General Electric Company Method and assembly for forming components having internal passages using a jacketed core
US9579714B1 (en) 2015-12-17 2017-02-28 General Electric Company Method and assembly for forming components having internal passages using a lattice structure
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CN112399908B (zh) * 2018-06-25 2023-04-07 考里安公司 形成主模、铸模的方法以及制备微结构阵列的方法

Also Published As

Publication number Publication date
WO2008138302A1 (fr) 2008-11-20
DE102007023152A1 (de) 2008-11-20
US20100304064A1 (en) 2010-12-02

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