EP2450127A2 - Hochtemperatur-Druckgießvorrichtung und Verfahren dafür - Google Patents

Hochtemperatur-Druckgießvorrichtung und Verfahren dafür Download PDF

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Publication number
EP2450127A2
EP2450127A2 EP11187817A EP11187817A EP2450127A2 EP 2450127 A2 EP2450127 A2 EP 2450127A2 EP 11187817 A EP11187817 A EP 11187817A EP 11187817 A EP11187817 A EP 11187817A EP 2450127 A2 EP2450127 A2 EP 2450127A2
Authority
EP
European Patent Office
Prior art keywords
die casting
high temperature
carbide
barrier coating
recited
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
EP11187817A
Other languages
English (en)
French (fr)
Other versions
EP2450127B1 (de
EP2450127A3 (de
Inventor
Mario P. Bochiechio
Lea Kennard Castle
Russell A. Beers
Mark F. Bartholomew
Douglas M. Berczik
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 EP2450127A2 publication Critical patent/EP2450127A2/de
Publication of EP2450127A3 publication Critical patent/EP2450127A3/de
Application granted granted Critical
Publication of EP2450127B1 publication Critical patent/EP2450127B1/de
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
    • 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 to die casting and, more specifically, a die casting system that has the ability to operate at high temperatures.
  • die casting is a process that includes moving molten metal into a die cavity to form a desired shape.
  • the process typically includes transporting the molten metal into the die cavity, holding the metal in the cavity for a period of time until the casting solidifies, removing the casting from the die cavity, and trimming the casting to remove any scrap.
  • a disclosed high temperature die casting system includes a die casting tool that has dies that are adapted for forming a component. Due to the nature of the process, the die casting tool is operable to heat and maintain a temperature of the dies above 500°F (260°C). At least a portion of the die casting tool that is exposed for contact with molten die casting material has a substrate and barrier coating on the substrate to protect from the molten die casting material.
  • a high temperature die casting system in another aspect, includes a die casting tool having a substrate and a barrier coating on the substrate.
  • the barrier coating is a material selected from partially or fully stabilized zirconia, titanium nitride, tungsten carbide, silicon carbide, silicon nitride, titanium carbide, silicon-oxygen-aluminum-nitrogen, hafnium carbide, zirconium carbide, and combinations thereof.
  • An exemplary method for a high temperature die casting system includes maintaining a die casting tool having dies that are adapted for forming a component at a temperature above 500°F (260°C), and using a barrier coating on at least a portion of the die casting tool that is exposed for contact with molten die casting material to protect the underlying substrate of the die casting tool from contact with the molten die casting material.
  • Figure 1 illustrates a die casting system 10 including a reusable die 12 having a plurality of die elements 14, 16 that function to cast a component 15.
  • the component 15 could include aeronautical components, such as a gas turbine engine blade or vane, or nonaeronautical components.
  • two die elements 14, 16 are depicted by Figure 1 , it should be understood that the die 12 could include more or fewer die elements, as well as other parts and other configurations.
  • the die 12 is assembled by positioning the die elements 14, 16 together and holding the die elements 14, 16 at a desired position via a mechanism 18.
  • the mechanism 18 could include a clamping mechanism of appropriate hydraulic, pneumatic, electromechanical, and/or other configurations.
  • the mechanism 18 also separates the die elements 14, 16 subsequent to casting.
  • the die elements 14, 16 include internal surfaces that cooperate to define a die cavity 20.
  • the die elements 14, 16 may additionally include one or more heating elements 17 for heating and maintaining the die cavity 20 at a desired temperature above 500°F (260°C).
  • the heating elements may heat the die elements 14, 16 up to 500°F (260°C) during initial start-up of the die elements 14, 16, maintain the desired temperature during operation of the die elements 14, 16, and maintain the desired temperature during thermal cycling as components are produced in the die casting system 10.
  • the heating elements 17 may be resistance heaters, induction heaters, a recirculating thermal medium, such as, but not limited to hot oil, or combinations of different kinds of heaters that are operable to heat the die cavity 20 to the desired temperature and then maintain that temperature (e.g., via non-application of heat or in combination with a cooling element).
  • a recirculating thermal medium such as, but not limited to hot oil
  • Traditional casting dies are not commonly equipped to specifically heat the cavity and may be present in the system for the purpose of removing excess heat from the die.
  • the elevated temperature of die elements 14, 16 serves to reduce the temperature differential between the die elements and the molten die casting material to reduce heat checking.
  • a shot tube 24 is in fluid communication with the die cavity 20 via one or more ports 26 that extend into the die element 14, the die element 16 or both.
  • a shot tube plunger 28 is received within the shot tube 24 and is moveable between a retracted and injected position (in the direction of arrow A) within the shot tube 24 by a mechanism 30.
  • a shaft 31 extends between the mechanism 30 and the shot tube plunger 28.
  • the mechanism 30 could include a hydraulic assembly or other suitable system, including, but not limited to, pneumatic, electromechanical, hydraulic or any combination of systems.
  • the shot tube 24 is positioned to receive a charge of material from a melting unit 32, such as a crucible, for example.
  • the melting unit 32 may utilize any known technique for melting an ingot of metallic material to prepare molten metal for delivery to the shot tube 24, such as will be further discussed below.
  • the charge of material is melted into molten metal by the melting unit 32 at a location that is separate from the shot tube 24 and the die 12.
  • the example melting unit 32 is positioned in relative close proximity to the die casting system 10 to reduce the transfer distance of the charge of material between the melting unit 32 and the die casting system 10.
  • Materials used to die cast a component 15 with the die casting system 10 include, but are not limited to, nickel-based super alloys, cobalt-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 other high melting temperature materials may be utilized to die cast a component 15. As used in this disclosure, the term "high melting temperature material" is intended to include materials having a melting temperature of approximately 1500°F (815°C) and higher.
  • the charge of material is transferred from the melting unit 32 to the die casting system 10.
  • the charge of material may be poured into a pour hole 33 of the shot tube 24.
  • a sufficient amount of molten metal is poured into the shot tube to fill the die cavity 20.
  • the shot tube plunger 28 is actuated to inject the charge of material under pressure from the shot tube 24 into the die cavity 20 to cast the component 15.
  • the die casting system 10 could be configured to cast multiple components in a single shot.
  • the die casting system 10 can be positioned within a vacuum chamber 34 that includes a vacuum source 35.
  • a vacuum is applied in the vacuum chamber 34 via the vacuum source 35 to render a vacuum die casting process.
  • the vacuum chamber 34 provides a non-reactive environment for the die casting system 10 that reduces reaction, contamination or other conditions that could detrimentally affect the quality of the die cast component, such as gas entrapment or the formation of oxides or nitrides within the die cast component that can occur from exposure to atmospheric gasses.
  • the vacuum chamber 34 is maintained at a pressure between 1x10 -3 Torr and 1x10 -4 Torr, although other pressures are contemplated.
  • each of the melting unit 32, the shot tube 24 and the die 12 are positioned within the vacuum chamber 34 during the die casting process such that the melting, injecting and solidifying of the high melting temperature material are all performed under vacuum.
  • the chamber 34 is backfilled with an inert gas, such as Argon, for example.
  • the example die casting system 10 of Figure 1 is illustrative only and could include more or fewer sections, parts and/or components. This disclosure extends to all forms of die casting, including but not limited to, horizontal, inclined, or vertical die casting systems and other die casting configurations.
  • the die casting system 10 utilizes a barrier coating 40 that protects the die casting system 10 from the effects of the high temperature molten die casting material.
  • the die casting system 10 includes the barrier coating 40 on at least a portion of the tool surfaces that are exposed for contact with the molten die casting material, to alleviate heat checking or other influences of the high temperature die casting material.
  • the components of the die casting system 10 that has a surface that contacts the molten metal is considered to be a die casting tool or component.
  • the surfaces of the die cavity 20, shot tube 24, shot tube plunger 28, melting unit 32, pour hole 33, and any runners or gates may include the barrier coating 40.
  • Figure 2 illustrates a selected portion of one such area that includes the barrier coating 40 on a substrate 42 of a given die casting tool.
  • the barrier coating 40 is deposited directly onto the surface of the substrate 42.
  • the substrate 42 may be any suitable material for the given component.
  • the substrate 42 may be a superalloy, such as a nickel and/or cobalt alloy. It is to be understood, however, that the material of the substrate 42 is not limited to any particular composition and one of ordinary skill in the art would be able to recognize suitable materials to meet their particular needs.
  • the barrier coating 40 forms a thermal barrier between the molten die casting material and the underlying substrate 42.
  • the material of the barrier coating 40 has a relatively high thermal resistance.
  • the barrier coating 40 may be a ceramic material, such as an oxide, a nitride, a carbide, a zirconia material, a gadolinia material or combinations thereof.
  • the oxide may be a combination of several different oxides, including at least one oxide and the balance comprising a first oxide.
  • the first oxide may be selected from the group consisting of zirconia, ceria, and hafnia.
  • the at least one oxide may have a formula A 2 O 3 , where A is selected from the group consisting of La, Pr, Nd, Sm, Eu, Th, In, Sc, Y, Dy, Ho, Er, Tm, Yb, Lu, and mixtures thereof.
  • the carbide may be a refractory metal carbide, such as a carbide of tungsten, niobium, tantalum, rhenium, or molybdenum. Additional carbide materials include silicon, titanium, hafnium, zirconium, or combinations thereof.
  • the barrier coating 40 is a partially or fully stabilized zirconia, titanium nitride, silicon nitride, a silicon-aluminum-oxy-nitride (SiAlON), boron nitride, aluminum nitride, alumina (e.g., alpha-alumina), or any combination thereof.
  • the barrier coating 40 is gadolinia and zirconia and may include 5-50 mol% gadolinia. The gadolinia and zirconia may include fluorite and a pyrochlore structure.
  • the barrier coating 40 may be or may include a metallic coating.
  • the metallic coating may be a platinum group metal, such as ruthenium, rhodium, palladium, osmium, iridium, platinum and combinations thereof.
  • the metallic coating may be a nickel alloy.
  • the nickel alloy may consist essentially of up to 15 wt% cobalt, 5-18 wt% chromium, 7.5-12 wt% aluminum, 0.1-1.0 wt% yttrium, up to 0.06 wt% hafnium, up to 0.3 wt% silicon, 3-10 wt% tantalum, up to 5 wt% tungsten, 1-6 wt% rhenium, up to 10 wt% molybdenum, and a balance of nickel and any impurities.
  • Figure 3 illustrates another example component that is similar to the example shown in Figure 2 except that the component additionally includes a bond coat 44 that mitigates any thermal expansion mismatch between the material of the substrate 42 and the material of the barrier coating 40.
  • the material of the bond coat 44 may be MCrAIY (where the M comprises at least one of nickel, cobalt, iron, or a combination thereof, Cr is chromium, Al is aluminum, and Y is yttrium), gamma-gamma prime nickel alloy, a nickel-based superalloy, or combinations thereof.
  • the gamma-gamma prime nickel alloy may generally have a microstructure comprising nickel metal with phases of Ni3(AlTi) dispersed throughout the nickel metal.
  • One example nickel-based superalloy has a nominal composition of 22 wt.% cobalt, 17 wt.% chromium, 12.5 wt.% aluminum, 0.6 wt.% yttrium, 0.4 wt.% silicon, 0.25wt.% hafnium, and a balance of nickel and any impurities.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
  • Coating By Spraying Or Casting (AREA)
EP11187817.9A 2010-11-05 2011-11-04 Hochtemperatur-Druckgießvorrichtung und Verfahren dafür Not-in-force EP2450127B1 (de)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US12/940,362 US20120111525A1 (en) 2010-11-05 2010-11-05 High temperature die casting apparatus and method therefor

Publications (3)

Publication Number Publication Date
EP2450127A2 true EP2450127A2 (de) 2012-05-09
EP2450127A3 EP2450127A3 (de) 2016-07-13
EP2450127B1 EP2450127B1 (de) 2019-10-09

Family

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Family Applications (1)

Application Number Title Priority Date Filing Date
EP11187817.9A Not-in-force EP2450127B1 (de) 2010-11-05 2011-11-04 Hochtemperatur-Druckgießvorrichtung und Verfahren dafür

Country Status (3)

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US (1) US20120111525A1 (de)
EP (1) EP2450127B1 (de)
SG (1) SG180159A1 (de)

Families Citing this family (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN102527982B (zh) * 2011-12-15 2015-05-13 比亚迪股份有限公司 非晶合金压铸设备及非晶合金压铸工艺
US20170356304A1 (en) * 2016-06-13 2017-12-14 General Electric Company Systems and methods for reducing fluid viscosity in a gas turbine engine
US10682691B2 (en) * 2017-05-30 2020-06-16 Raytheon Technologies Corporation Oxidation resistant shot sleeve for high temperature die casting and method of making
CN110684979B (zh) * 2019-11-01 2022-06-21 江苏锋泰工具有限公司 一种冷喷涂制备硬质合金涂层的方法
US20220290289A1 (en) * 2021-03-10 2022-09-15 Vapor Technologies, Inc. Pvd coatings for aluminum die casting molds

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US2621122A (en) * 1946-10-09 1952-12-09 Rolls Royce Alloy for heat and corrosion resisting coating
GB8503876D0 (en) * 1985-02-15 1985-03-20 Ontario Research Foundation Chemical vapour deposition of titanium borides
US20020005233A1 (en) * 1998-12-23 2002-01-17 John J. Schirra Die cast nickel base superalloy articles
AUPP939099A0 (en) * 1999-03-23 1999-04-15 Cast Centre Pty Ltd Die coatings for gravity and low pressure diecasting
US6470550B1 (en) * 1999-11-11 2002-10-29 Shear Tool, Inc. Methods of making tooling to be used in high temperature casting and molding
US6786272B2 (en) * 2000-11-30 2004-09-07 Copper Development Association, Inc. Apparatus and method for die casting
US6702886B2 (en) * 2001-11-20 2004-03-09 Alcoa Inc. Mold coating
US6730422B2 (en) * 2002-08-21 2004-05-04 United Technologies Corporation Thermal barrier coatings with low thermal conductivity
US6986381B2 (en) * 2003-07-23 2006-01-17 Santoku America, Inc. Castings of metallic alloys with improved surface quality, structural integrity and mechanical properties fabricated in refractory metals and refractory metal carbides coated graphite molds under vacuum
DE102007046410A1 (de) * 2007-09-24 2009-04-02 Volkswagen Ag Gießereiwerkzeug und Verfahren zur Herstellung eines solchen Werkzeuges sowie dessen Verwendung
US8418744B2 (en) * 2009-03-24 2013-04-16 Nonferrous Materials Technology Development Centre Molten metal casting die

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Also Published As

Publication number Publication date
US20120111525A1 (en) 2012-05-10
EP2450127B1 (de) 2019-10-09
EP2450127A3 (de) 2016-07-13
SG180159A1 (en) 2012-05-30

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