EP2450126A2 - Druckgusssystem und Verfahren zur Verwendung von Materialien mit hohen Schmelztemperaturen - Google Patents

Druckgusssystem und Verfahren zur Verwendung von Materialien mit hohen Schmelztemperaturen Download PDF

Info

Publication number
EP2450126A2
EP2450126A2 EP11187963A EP11187963A EP2450126A2 EP 2450126 A2 EP2450126 A2 EP 2450126A2 EP 11187963 A EP11187963 A EP 11187963A EP 11187963 A EP11187963 A EP 11187963A EP 2450126 A2 EP2450126 A2 EP 2450126A2
Authority
EP
European Patent Office
Prior art keywords
die
shot tube
casting system
die casting
plunger
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Withdrawn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
EP11187963A
Other languages
English (en)
French (fr)
Other versions
EP2450126A3 (de
Inventor
Mario P. Bochiechio
Dilip M. Shah
Lea Kennard Castle
Douglas M. Berczik
John Joseph Marcin
Carl R. Verner
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.)
Raytheon Technologies Corp
Original Assignee
United Technologies Corp
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 United Technologies Corp filed Critical United Technologies Corp
Publication of EP2450126A2 publication Critical patent/EP2450126A2/de
Publication of EP2450126A3 publication Critical patent/EP2450126A3/de
Withdrawn legal-status Critical Current

Links

Images

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
    • B22D17/20—Accessories: Details
    • B22D17/2015—Means for forcing the molten metal into the die
    • B22D17/2023—Nozzles or shot sleeves
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
    • B22D17/20—Accessories: Details
    • B22D17/22—Dies; Die plates; Die supports; Cooling equipment for dies; Accessories for loosening and ejecting castings from dies
    • B22D17/2209—Selection of die materials

Definitions

  • This disclosure relates generally to casting and, more particularly, to a die casting system for casting high temperature materials.
  • Die casting involves injecting molten metal directly into a reusable die to yield a net-shaped component. Die casting has typically been used to produce components that do not require high thermal mechanical performance. For example, die casting is commonly used to produce components made from relatively low melting temperature metals, such as, but not limited to: aluminum, zinc, magnesium, and copper. The products produced from these alloy systems are not generally subjected to extreme operating conditions.
  • Gas turbine engines include multiple components that are subjected to extreme temperatures during operation.
  • the compressor section and turbine section of the gas turbine engine each include blades and vanes that are subjected to relatively extreme temperatures, such as temperatures exceeding approximately 1500°F (815°C).
  • Gas turbine engine components for use in these applications are produced through several processes, such as, but not limited to, investment casting and forging.
  • Investment casting involves pouring molten metal into a ceramic shell having a cavity in the shape of the component to be cast.
  • the shape of the component to be produced is derived from a wax pattern or SLA pattern to form the exterior shape of the component.
  • the investment casting process is capital intensive, requires significant manual labor, and can be time intensive to produce the final component.
  • Forging of a component is accomplished through the application of localized forces to the desired metal using shaped tooling to plastically deform the metal into the final shape. While forging is generally less expensive than investment casting there is still a significant amount of lead time and capital investment required to produce components by this methodology. Wrought product can be subsequently machined into the desired shape, but is less cost effective for large volumes of components due to excessive material losses due to machining.
  • An example die casting system includes a die comprised of a plurality of die components that define a die cavity, metal delivery system, and part removal system configured to receive a molten metal.
  • One or more of the die components comprises a material or materials that are suitable for use with the molten metal and has a melting temperature above 815 degrees Celsius.
  • An example die casting system includes a die comprised of a plurality of die components that define a die cavity configured to receive a molten metal, wherein at least one of the plurality of die components comprises a material selected from a group consisting of a nickel based super alloy, a cobalt based super alloy, an iron-nickel based super alloy, a suitably alloyed iron based alloy, a suitably alloyed copper alloy, and a refractory metal alloy where the refractory metal is either: tungsten, molybdenum, rehenium, niobium, or tantalum.
  • An example die casting system includes a die comprised of a plurality of die components that define a die cavity configured to receive a molten metal that has a melting temperature above 815 degrees Celsius.
  • One of the die components comprises a ceramic material, or a composite material such as: a metal matrix composite, a ceramic matrix composite, or a combination of independent ceramic and metallic components that comprise the die components.
  • an example die casting system 50 including a reusable die 52 having a plurality of die elements 54, 56 that function to cast a component 55.
  • a reusable die 52 having a plurality of die elements 54, 56 that function to cast a component 55.
  • die elements 54, 56 are depicted in Figure 1 , it should be understood that the die 52 could include more or fewer die elements, as well as other parts and configurations.
  • the die 52 is assembled by positioning the die elements 54, 56 together and holding the die elements 54, 56 at a desired positioning via a mechanism 58.
  • the mechanism 58 could include a clamping mechanism of appropriate hydraulic, pneumatic, electromechanical and/or other configurations.
  • the mechanism 58 also separates the die elements 54, 56 subsequent to casting.
  • the die elements 54, 56 define internal surfaces 62 that cooperate to define a die cavity 60.
  • a shot tube 64 is in fluid communication with the die cavity 60 via one or more ports 66 located in the die element 54, the die element 56, or both.
  • a plunger tip and rod 68 are received within the shot tube 64 and is moveable between a retracted and injection position (in the direction of arrow A) within the shot tube 64 by a mechanism 80.
  • the mechanism 80 could include a hydraulic assembly or other suitable mechanism, including, but not limited to, hydraulic, pneumatic, electromechanical, or any combination thereof.
  • the shot tube 64 is positioned to receive a molten metal from a melting unit 82, such as a crucible, for example.
  • the melting unit 82 may utilize any known technique for melting an ingot of metallic material to prepare a molten metal for delivery to the shot tube 64, including but not limited to, vacuum induction melting, electron beam melting, induction skull melting, and resistance melting.
  • the molten metal to be used to manufacture the part is melted in the melting unit 82 at a location that is separate from the shot tube 64 and the die cavity 60.
  • the melting unit 82 is positioned in close proximity to the shot tube 64 to reduce the required transfer distance between the molten metal and the shot tube 64.
  • Example molten metals capable of being used to die cast a component 55 include, but are not limited to, nickel based super alloys, titanium alloys, high temperature aluminum alloys, copper based alloys, iron alloys, molybdenum, tungsten, niobium, or other refractory metals. This disclosure is not limited to the disclosed alloys, and it should be understood that any material having a high melting temperature may be utilized to die cast the component 55. As used herein, the term "high melting temperature” is intended to describe component materials having a melting temperature of approximately 1500°F (815°C) or higher.
  • the molten metal is transferred from the melting unit 82 to the shot tube 64 in a known manner, such as pouring the molten metal into a pour hole 63 in the shot tube 64, for example.
  • a sufficient amount of molten metal is poured into the shot tube 64 to fill the die cavity 60.
  • the shot tube plunger 68 is actuated to inject the molten metal under pressure from the shot tube 64 into the die cavity 60 to cast the component 55.
  • the die casting system 50 could be configured to cast multiple components in a single shot.
  • the example die casting system 50 depicted in Figure 1 is illustrative only and could include more or less sections, parts and/or components. This disclosure extends to all forms of die casting, including but not limited to, horizontal or vertical, or inclined die casting systems.
  • Figures 3A and 3B illustrate portions of the die casting system 50 during casting ( Figure 3A ) and after the die elements 54, 56 separate ( Figure 3B ).
  • the die elements 54, 56 are disassembled relative to the component 55 by opening the die 52 via the mechanism 58.
  • ejector pins 84 are used to move the component 55 from the die cavity 60.
  • the example die casting system 50 includes portions that are made from high temperature system materials that are able to withstand high temperatures associated with casting the molten metal into the component 55.
  • the die elements 54, 56 are made entirely of the high temperature system material.
  • a portion of the die elements 54, 56 are made of the high temperature system material.
  • the areas of the cavity 70 establishing areas of the component 55 prone to microfractures or thermo-mechanical induced fatigue, such as tight radii areas of the cast component, could be made of the high temperature system material.
  • the areas of the die elements 54, 56 establishing the cavity could be coated with the high temperature system material.
  • portions of the shot tube 64, the shot tube plunger 68, or the ejector pins 84 include the high temperature system material in some examples.
  • the example high temperature system material does not reactively interact with the molten material. That is, there is no substantial chemical reaction, melting, welding, soldering, or alloying between the high temperature system material and the molten material.
  • the die elements 54, 56 could incorporate the high temperature system material by casting, machining, slip casting, injection molding, isostatic pressing (hot or cold), sintering, stamping, forging, direct metal laser sintering etc.
  • Example materials that could be used as the high temperature system material include metallic materials, such as a nickel based super alloy, a cobalt based super alloy, a iron-nickel based super alloy, a suitably alloyed iron based alloy, a suitably alloyed copper alloy, or a refractory metal (tungsten, molybdenum, rehenium, niobium, or tantalum) based alloy.
  • metallic materials such as a nickel based super alloy, a cobalt based super alloy, a iron-nickel based super alloy, a suitably alloyed iron based alloy, a suitably alloyed copper alloy, or a refractory metal (tungsten, molybdenum, rehenium, niobium, or tantalum) based alloy.
  • tungsten, molybdenum, rehenium, niobium, or tantalum refractory metal
  • Example nickel based super alloys include: IN100, IN713C, IN792 forged; First generation nickel base single crystal alloys (0% Rhenium) such as those disclosed in US 4209348 and US4597809 ; Second generation nickel base single crystal alloys (3% Rhenium) such as those disclosed in US4719080 ; Third generation nickel base single crystal alloys (6% Rhenium) such as those disclosed in US5366695 ; Fourth generation nickel base single crystal alloys (6% Rhenium, 3% Ruthenium) such as those disclosed in US6007645 ; Fifth generation nickel base nickel base single crystal alloys (6+% Rhenium, 6+% Ruthenium) such as TMS-173; Directionally solidified first generation (0% Rhenium) columnar structure alloys such as those disclosed in US3785809 ; and second generation (3% Rhenium) columnar structure alloys such as those disclosed in US5068084 .
  • Example nickel-iron super alloys include Invar 909, IN718.
  • Example alloyed based iron alloys include: H23, H42, M35, M36, M42, M46, M62 and Greek Ascoloy.
  • Example cobalt cast alloys include Mar-M-509, and Stellite 31.
  • Example refractory metal alloys include: Anvilloy 1150, TZM (tungsten-molybdenum-zirconium), molybdenum-rhenium systems, tantalum -10% tungsten, and tungsten-rhenium systems.
  • Example materials that can be used as the high temperature system material include ceramic materials, such as boron nitride, silicon nitride, silicon aluminum oxy nitride (SiAlON), aluminum nitride, aluminum oxide, silicon carbide, titanium carbide, tungsten carbide, zirconium oxide, boron carbide, titanium diboride, niobium boride, zirconium boride, hafnium diboride, niobium carbide, zirconium carbide, hafnium carbide, graphite etc.
  • ceramic materials such as boron nitride, silicon nitride, silicon aluminum oxy nitride (SiAlON), aluminum nitride, aluminum oxide, silicon carbide, titanium carbide, tungsten carbide, zirconium oxide, boron carbide, titanium diboride, niobium boride, zirconium boride, hafnium diboride, niobium carbide
  • Example materials that can be used as the high temperature system material include metal matrix composite materials, such as copper-tungsten, copper-molybdenum, copper-molybdenumcopper-copper, copper-niobium, Silvar, aluminium silicon carbide.
  • Example materials that can be used as the high temperature system material include ceramic matrix composite materials, such as C-SiC, SiC-SiC, SiC-Si 3 N 4 , C-ZrC, C-HfC, C-SiC-ZrC, C-SiC-HfC, C-TaC and C-TaC-HfC.
  • ceramic matrix composite materials such as C-SiC, SiC-SiC, SiC-Si 3 N 4 , C-ZrC, C-HfC, C-SiC-ZrC, C-SiC-HfC, C-TaC and C-TaC-HfC.
  • the example component 55 is casted using the example die casting system 50 described above.
  • the die casted component 55 is a blade for the gas turbine engine (not shown), such as a turbine blade for a turbine section of the gas turbine engine.
  • this disclosure is not limited to the casting of blades.
  • the example die casting system 50 of this disclosure may be utilized to cast aeronautical components including blades, vanes, combustor panels, blade outer air seals, or any other component subjected to extreme environments, including non-aeronautical components.
  • the example component 55 includes tightly radiused areas 86 that are more susceptible to thermo mechanical fatigue that other areas of the component 55.
  • the areas of the die elements 54, 56 that interface with the areas 86 include a layer of high temperature system material, for example.
  • a die casting system that includes system materials that are have a relatively high melt point and that are non-reactive with a component material.
  • the system materials facilitate die casting of components that are made from component materials having a high melt point.
  • the system materials reduce thermo-mechanical fatigue in the cast component.
  • the system materials are effective for moving thermal energy away from the cast component.
  • the system materials absorb the heat input from molten metals.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
  • Turbine Rotor Nozzle Sealing (AREA)
EP11187963.1A 2010-11-05 2011-11-04 Druckgusssystem und Verfahren zur Verwendung von Materialien mit hohen Schmelztemperaturen Withdrawn EP2450126A3 (de)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US12/940,263 US20120111526A1 (en) 2010-11-05 2010-11-05 Die casting system and method utilizing high melting temperature materials

Publications (2)

Publication Number Publication Date
EP2450126A2 true EP2450126A2 (de) 2012-05-09
EP2450126A3 EP2450126A3 (de) 2016-01-06

Family

ID=44905708

Family Applications (1)

Application Number Title Priority Date Filing Date
EP11187963.1A Withdrawn EP2450126A3 (de) 2010-11-05 2011-11-04 Druckgusssystem und Verfahren zur Verwendung von Materialien mit hohen Schmelztemperaturen

Country Status (3)

Country Link
US (2) US20120111526A1 (de)
EP (1) EP2450126A3 (de)
SG (1) SG180155A1 (de)

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2016039715A1 (en) * 2014-09-08 2016-03-17 Siemens Aktiengesellschaft Hybrid die cast system for forming a component usable in a gas turbine engine
EP3287212A1 (de) * 2016-08-26 2018-02-28 United Technologies Corporation Niedrigmodulgiesskammer zum hochtemperatur-druckgiessen
EP3360624A1 (de) * 2017-02-08 2018-08-15 United Technologies Corporation Axialsymmetrisches einkristall-schussrohr für hochtemperaturdruckguss
EP3409400A1 (de) * 2017-05-30 2018-12-05 United Technologies Corporation Oxidationsbeständige giesshülse für den hochtemperaturdruckguss und verfahren zur herstellung

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN114737072B (zh) * 2022-04-21 2022-09-23 无锡凯斯特铸业有限公司 一种k417g镍基高温合金精炼制备以及成型方法

Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3785809A (en) 1971-06-15 1974-01-15 United Aircraft Corp Nickel-base superalloy
US4209348A (en) 1976-11-17 1980-06-24 United Technologies Corporation Heat treated superalloy single crystal article and process
US4597809A (en) 1984-02-10 1986-07-01 United Technologies Corporation High strength hot corrosion resistant single crystals containing tantalum carbide
US4719080A (en) 1985-06-10 1988-01-12 United Technologies Corporation Advanced high strength single crystal superalloy compositions
US5068084A (en) 1986-01-02 1991-11-26 United Technologies Corporation Columnar grain superalloy articles
US5366695A (en) 1992-06-29 1994-11-22 Cannon-Muskegon Corporation Single crystal nickel-based superalloy
US6007645A (en) 1996-12-11 1999-12-28 United Technologies Corporation Advanced high strength, highly oxidation resistant single crystal superalloy compositions having low chromium content

Family Cites Families (12)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3201835A (en) * 1963-03-11 1965-08-24 Titanium Metals Corp Casting refractory metals
US3532561A (en) * 1967-05-11 1970-10-06 Gen Electric Ferrous metal die casting process and products
US3841846A (en) * 1970-01-25 1974-10-15 Mallory & Co Inc P R Liquid phase sintered molybdenum base alloys having additives and shaping members made therefrom
US3810505A (en) * 1970-12-07 1974-05-14 R Cross Die casting method
US3988118A (en) * 1973-05-21 1976-10-26 P. R. Mallory & Co., Inc. Tungsten-nickel-iron-molybdenum alloys
JPS53105515A (en) * 1977-02-25 1978-09-13 Nissan Motor Die cast tool
EP0225523B1 (de) * 1985-11-30 1989-11-15 Akio Nakano Druckgiessform zum Gebrauch beim Giessen
JPH0730429B2 (ja) * 1986-12-16 1995-04-05 三菱マテリアル株式会社 分散強化型焼結合金鋼製ＺｎおよびＺｎ合金ダイカスト用金型
JPS63203262A (ja) * 1987-02-19 1988-08-23 Hitachi Metals Ltd 金型
US20020005233A1 (en) * 1998-12-23 2002-01-17 John J. Schirra Die cast nickel base superalloy articles
DE69923930T2 (de) * 1998-12-23 2006-04-06 United Technologies Corp., Hartford Vorrichtung zum Druckgiessen von Material mit hohem Schmelzpunkt
US6479013B1 (en) * 2000-08-10 2002-11-12 Sumitomo Metal Industries, Ltd. Casting components made from a tool steel

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3785809A (en) 1971-06-15 1974-01-15 United Aircraft Corp Nickel-base superalloy
US4209348A (en) 1976-11-17 1980-06-24 United Technologies Corporation Heat treated superalloy single crystal article and process
US4597809A (en) 1984-02-10 1986-07-01 United Technologies Corporation High strength hot corrosion resistant single crystals containing tantalum carbide
US4719080A (en) 1985-06-10 1988-01-12 United Technologies Corporation Advanced high strength single crystal superalloy compositions
US5068084A (en) 1986-01-02 1991-11-26 United Technologies Corporation Columnar grain superalloy articles
US5366695A (en) 1992-06-29 1994-11-22 Cannon-Muskegon Corporation Single crystal nickel-based superalloy
US6007645A (en) 1996-12-11 1999-12-28 United Technologies Corporation Advanced high strength, highly oxidation resistant single crystal superalloy compositions having low chromium content

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2016039715A1 (en) * 2014-09-08 2016-03-17 Siemens Aktiengesellschaft Hybrid die cast system for forming a component usable in a gas turbine engine
CN106604791A (zh) * 2014-09-08 2017-04-26 西门子公司 用于形成可用于燃气涡轮发动机中的部件的混合压铸系统
EP3287212A1 (de) * 2016-08-26 2018-02-28 United Technologies Corporation Niedrigmodulgiesskammer zum hochtemperatur-druckgiessen
US10245637B2 (en) 2016-08-26 2019-04-02 United Technologies Corporation Low modulus shot sleeve for high temperature die casting
EP3360624A1 (de) * 2017-02-08 2018-08-15 United Technologies Corporation Axialsymmetrisches einkristall-schussrohr für hochtemperaturdruckguss
EP3409400A1 (de) * 2017-05-30 2018-12-05 United Technologies Corporation Oxidationsbeständige giesshülse für den hochtemperaturdruckguss und verfahren zur herstellung

Also Published As

Publication number Publication date
US20190299278A1 (en) 2019-10-03
SG180155A1 (en) 2012-05-30
US20120111526A1 (en) 2012-05-10
EP2450126A3 (de) 2016-01-06

Similar Documents

Publication Publication Date Title
US20190299278A1 (en) Die casting system and method utilizing high melting temperature materials
US6676381B2 (en) Method and apparatus for casting near-net shape articles
EP2450125B1 (de) Maschinenkonfigurationen für ein Druckgusssystem
US20210346947A1 (en) Die casting system and method
US9908175B2 (en) Die casting system and method utilizing sacrificial core
CN107666977B (zh) 用于制造涡轮发动机的铝化钛叶片的方法
IL143931A (en) Injection molding of a material with a high melting temperature
EP2486994B1 (de) Schussrohrkolben für ein Druckgusssystem
US20160074933A1 (en) Die casting of component having integral seal
EP2450127B1 (de) Hochtemperatur-Druckgießvorrichtung und Verfahren dafür
EP2450124A2 (de) Giesskolben für ein Druckgusssystem
US7332123B2 (en) Method for manufacturing composite articles and the articles obtained therefrom
EP2450131B1 (de) Schmelzeinheit für ein Druckgusssystem
EP3360624A1 (de) Axialsymmetrisches einkristall-schussrohr für hochtemperaturdruckguss
EP2841224A1 (de) Spitzenteil eines injektionsrohrkolbens
GB2536483B (en) A method of Forming a Metal Component

Legal Events

Date Code Title Description
PUAI Public reference made under article 153(3) epc to a published international application that has entered the european phase

Free format text: ORIGINAL CODE: 0009012

AK Designated contracting states

Kind code of ref document: A2

Designated state(s): AL AT BE BG CH CY CZ DE DK EE ES FI FR GB GR HR HU IE IS IT LI LT LU LV MC MK MT NL NO PL PT RO RS SE SI SK SM TR

AX Request for extension of the european patent

Extension state: BA ME

PUAL Search report despatched

Free format text: ORIGINAL CODE: 0009013

AK Designated contracting states

Kind code of ref document: A3

Designated state(s): AL AT BE BG CH CY CZ DE DK EE ES FI FR GB GR HR HU IE IS IT LI LT LU LV MC MK MT NL NO PL PT RO RS SE SI SK SM TR

AX Request for extension of the european patent

Extension state: BA ME

RIC1 Information provided on ipc code assigned before grant

Ipc: B22D 17/20 20060101AFI20151201BHEP

Ipc: B22D 17/22 20060101ALI20151201BHEP

17P Request for examination filed

Effective date: 20160706

RBV Designated contracting states (corrected)

Designated state(s): AL AT BE BG CH CY CZ DE DK EE ES FI FR GB GR HR HU IE IS IT LI LT LU LV MC MK MT NL NO PL PT RO RS SE SI SK SM TR

RAP1 Party data changed (applicant data changed or rights of an application transferred)

Owner name: UNITED TECHNOLOGIES CORPORATION

17Q First examination report despatched

Effective date: 20180328

STAA Information on the status of an ep patent application or granted ep patent

Free format text: STATUS: THE APPLICATION HAS BEEN WITHDRAWN

18W Application withdrawn

Effective date: 20190902