EP2461922A1 - Résistance à la corrosion pour un procédé de lixivation - Google Patents

Résistance à la corrosion pour un procédé de lixivation

Info

Publication number
EP2461922A1
EP2461922A1 EP10808599A EP10808599A EP2461922A1 EP 2461922 A1 EP2461922 A1 EP 2461922A1 EP 10808599 A EP10808599 A EP 10808599A EP 10808599 A EP10808599 A EP 10808599A EP 2461922 A1 EP2461922 A1 EP 2461922A1
Authority
EP
European Patent Office
Prior art keywords
ceramic
leaching
metallic
cast
vessel
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Withdrawn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
EP10808599A
Other languages
German (de)
English (en)
Other versions
EP2461922A4 (fr
Inventor
Max Eric Schlienger
Michael Christopher Maguire
Michael Dean Maguire
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.)
Rolls Royce Corp
Original Assignee
Rolls Royce 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 Rolls Royce Corp filed Critical Rolls Royce Corp
Publication of EP2461922A1 publication Critical patent/EP2461922A1/fr
Publication of EP2461922A4 publication Critical patent/EP2461922A4/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Withdrawn legal-status Critical Current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
    • B22D29/00—Removing castings from moulds, not restricted to casting processes covered by a single main group; Removing cores; Handling ingots
    • B22D29/001—Removing cores
    • B22D29/002—Removing cores by leaching, washing or dissolving
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23F—NON-MECHANICAL REMOVAL OF METALLIC MATERIAL FROM SURFACE; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL; MULTI-STEP PROCESSES FOR SURFACE TREATMENT OF METALLIC MATERIAL INVOLVING AT LEAST ONE PROCESS PROVIDED FOR IN CLASS C23 AND AT LEAST ONE PROCESS COVERED BY SUBCLASS C21D OR C22F OR CLASS C25
    • C23F13/00—Inhibiting corrosion of metals by anodic or cathodic protection
    • C23F13/005—Anodic protection
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23F—NON-MECHANICAL REMOVAL OF METALLIC MATERIAL FROM SURFACE; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL; MULTI-STEP PROCESSES FOR SURFACE TREATMENT OF METALLIC MATERIAL INVOLVING AT LEAST ONE PROCESS PROVIDED FOR IN CLASS C23 AND AT LEAST ONE PROCESS COVERED BY SUBCLASS C21D OR C22F OR CLASS C25
    • C23F13/00—Inhibiting corrosion of metals by anodic or cathodic protection
    • C23F13/02—Inhibiting corrosion of metals by anodic or cathodic protection cathodic; Selection of conditions, parameters or procedures for cathodic protection, e.g. of electrical conditions
    • C23F13/06—Constructional parts, or assemblies of cathodic-protection apparatus
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23F—NON-MECHANICAL REMOVAL OF METALLIC MATERIAL FROM SURFACE; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL; MULTI-STEP PROCESSES FOR SURFACE TREATMENT OF METALLIC MATERIAL INVOLVING AT LEAST ONE PROCESS PROVIDED FOR IN CLASS C23 AND AT LEAST ONE PROCESS COVERED BY SUBCLASS C21D OR C22F OR CLASS C25
    • C23F2213/00—Aspects of inhibiting corrosion of metals by anodic or cathodic protection
    • C23F2213/30—Anodic or cathodic protection specially adapted for a specific object

Definitions

  • the present invention generally relates to leaching devices used to remove a core/mold/shell from a cast component, and more particularly, but not exclusively, to corrosion resistance for the cast component during a leaching process.
  • One embodiment of the present invention is a unique ability to provide corrosion resistance to a cast component during a leaching process.
  • Other embodiments include apparatuses, systems, devices, hardware, methods, and combinations for providing corrosion resistance during a core/mold leaching process from a cast component part. Further embodiments, forms, features, aspects, benefits, and advantages of the present application shall become apparent from the description and figures provided herewith.
  • FIG. 1 depicts one form of the present application.
  • Fig. 2 depicts an article having an object and a mold/core.
  • Fig. 3 depicts one form of the present application.
  • a mold used to receive a molten metal in an investment casting process is removed by a leaching process to reveal a cast article.
  • the present application will be describe with reference to metals however it is contemplated herein as useful with elemental metals, alloys, superalloys and intermetallic materials unless specifically provided to the contrary.
  • the mold can be made of a ceramic material and in one form is alumina.
  • the leaching process utilizes a leaching fluid that interacts with and removes the mold material, but in so doing the leaching fluid in the vicinity of the ceramic being leached can become less reactive. To replenish its effectiveness, the leaching fluid can be boiled to sweep away the depleted solution and allow fresh leaching fluid to take its place.
  • the leaching fluid can either be boiled through a conversion of liquid to vapor at, for example, a heat flux surface, or the leaching fluid can be placed in a superheated state where vapor can nucleate on a variety of surfaces within the system.
  • a superheated state can be accomplished by, for example, suddenly dropping system pressure when the leaching fluid is at or near an equilibrium state.
  • An electric power supply is used to create an electrolytic cell which discourages corrosion or other attacks of the cast article from the leaching fluid.
  • the power supply is used to provide a potential difference in the electrolytic cell in which the cast article can be configured as either an anode or a cathode.
  • multiple cast articles can be used in the system, some of which are configured as an anode and others as a cathode.
  • the power supply can be activated at any time and in one form in particular when the leaching fluid is being boiled to remove the ceramic mold.
  • an electrolytic device 50 is shown that is capable of protecting an object from corrosion when the object is at least partially immersed in a working fluid 52.
  • the object can take a variety of forms in various embodiments.
  • the object can be metallic, it can take the form of an alloy, and it can be produced using a casting process such as, but not limited to, investment casting. Other forms and variations of the object are also contemplated.
  • the working fluid 52 can be a caustic fluid used as a leachant in an investment casting mold removal process, an example of which will be described further below.
  • the working fluid can be KOH.
  • the working fluid 52 can also be NaOH, or mixtures of NaOH and KOH, among other possibilities, combinations, and mixtures.
  • the electrolytic device 50 includes an anode 54 and a cathode 56 that can be driven to a potential difference by a power supply (not shown). Either the anode 54 or the cathode 56 can be coupled with such things as the object, a container that holds the working fluid 52, or with any other of a variety of structures. It will be appreciated, therefore, that any of the object, container, or other structures can themselves serve as the anode 54 or the cathode 56 of the electrolytic device 50. It will also be appreciated that whatever the ultimate form, either or both the anode 54 or the cathode 56 can be immersed completely into the working fluid or have a surface directly in contact with the working fluid 52. Some embodiments of the electrolytic device 50 are described further below.
  • Fig. 2 depicts one form of an article 58 that can be used with the electrolytic device 50.
  • the article 58 includes an object 60 coupled with a mold 62.
  • the term mold as used herein can include a shell and/or a core, and each can be used interchangeably.
  • the object 60 can be a cast metallic alloy and the mold 62 can be an alumina mold.
  • the present application contemplates a wide variety of ceramic materials for the shell and/or core.
  • the shell and core can be formed of dissimilar material.
  • the present application contemplates materials other than ceramics for use as the shell and/or core.
  • Other variations either in the composition of the object 58 or the type of mold 62 are also contemplated herein.
  • the object 60 can be produced using a variety of techniques such as directional solidification, and can also take on crystal structures such as single crystal.
  • the metallic alloy can be a nickel based alloy, among other possibilities.
  • the mold 62 is produced using free-form fabrication techniques, such as but not limited to virtual pattern casting, laser stereolithography, and others. In one embodiment the mold 62 can be used to create a cast shape of the object 60 in the form of an aircraft gas turbine engine blade.
  • aircraft includes, but is not limited to, helicopters, airplanes, unmanned space vehicles, fixed wing vehicles, variable wing vehicles, rotary wing vehicles, unmanned combat aerial vehicles, tailless aircraft, hover crafts, and other airborne and/or extraterrestrial (spacecraft) vehicles.
  • helicopters airplanes
  • unmanned space vehicles fixed wing vehicles
  • variable wing vehicles variable wing vehicles
  • rotary wing vehicles unmanned combat aerial vehicles
  • tailless aircraft hover crafts
  • other airborne and/or extraterrestrial (spacecraft) vehicles include, for example, industrial applications, power generation, pumping sets, naval propulsion, weapon systems, security systems, perimeter defense/security systems, and the like known to one of ordinary skill in the art.
  • the corrosion resistance system 64 includes a container 66 having the working fluid 52 and article 58 disposed within it.
  • the container is made of nickel.
  • the corrosion resistance system 64 also includes an inert gas purge 68 operable to provide an inert gas within the container 66 above the working fluid 52, and a pump system 70 capable of withdrawing a gas, whether inert or otherwise, from within the container 66. Not all embodiments need have the one or both of the inert gas purge 68 or the pump system 70.
  • the corrosion resistance system 64 includes an electrode 72 coupled with a power supply 75.
  • the electrode is metal which can made from platinum, among possible others.
  • the electrode includes an end at least partially submerged within the working fluid 52.
  • the corrosion resistance system 64 can be used in conjunction with a process to leach a ceramic core from the article 58.
  • a leaching process can use heater 74 useful in providing a heat for a leaching process and to boil the working fluid 52 and leach the mold 62.
  • Other mechanisms in addition or alternative to the heater 74 can also be used to heat and/or boil the working fluid 52.
  • a pressure of the working fluid 52 can be lowered to a point in which the working fluid 52 is at a superheated state thus encouraging nucleation and subsequent boiling of the working fluid 52.
  • Mechanisms such as pumps can be used to change the pressure in the working fluid 52.
  • the pump system 70 can be used in some embodiments to not only withdraw a gas, whether inert or otherwise, from the container 66, but can also be used to provide a gas, whether inert or otherwise, into the container 66 to change the pressure of the working fluid 52. It will be appreciated, therefore, that either the inert gas purge 68 or the pump system 70 can be used to vary the pressure of the working fluid 52.
  • the power supply 75 can take the form of any variety of devices capable of providing and/or regulating a voltage or current.
  • the power supply 75 can be a DC power supply.
  • the power supply is electrically coupled with the container 66.
  • the power supply 75 is further electrically coupled with the article 58 to provide either anodic or cathodic protection.
  • the power supply 75 can be electrically coupled with the article 58 through a wire 76 extending between the article 58 and the container 66. Such a wire can be fixed within the container 66 by drilling and taping a hole.
  • the power supply 75 can be electrically coupled with the article 58 through a basket 78, such as a wire frame basket.
  • the basket 78 can be electrically coupled with the power supply by contacting the container 66 or through an intervening conductor such as the wire 76.
  • a potential difference can be provided by the power supply 75 and the article 58 configured to be operated as an anode. As the potential difference is increased above a certain value the material of the article 58, and specifically the object 60, enters a passive region in which relatively little or no corrosion process is present.
  • a potential difference can be provided by the power supply 75 and the article 58 configured to be operated as a cathode.
  • multiple articles 58 can be disposed within container 66 and the corrosion resistance system 64 can be operated to provide anodic or cathodic protection.
  • one or more articles 58 can be configured as an anode and one or more articles 58 can be configured as cathodes.
  • operating the corrosion resistance system 64 for an extended period of time can be useful in removing or mitigating oxide coatings on the inside of the container 66 and/or on the basket 78.
  • the inert gas purge 68 can include the devices depicted in Fig. 3 but not all embodiments need include each of the devices.
  • the inert gas purge 68 can provide a gas to the container 66 at a variety of pressures and temperatures.
  • the inert gas purge 68 can deliver a gas such as, but not limited to, argon.
  • the pump system 70 can include the devices depicted in Fig. 3 but not all embodiments need include each of the devices.
  • the pump system can be used to extract a gas such as hydrogen from the container 66.
  • an oxygen getter can be used to remove oxygen present within the container 66.
  • Such an oxygen getter can take the form of, but not limited to, titanium, wood chips, etc.

Landscapes

  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Prevention Of Electric Corrosion (AREA)

Abstract

L'invention porte sur un système de résistance à la corrosion qui peut être utilisé en association avec un dispositif de lixivation pour le retrait d'un moule à partir d'un composant moulé. Le système de résistance à la corrosion comprend un récipient ayant un fluide de travail, tel qu'un fluide caustique. Un composant moulé et un moule sont disposés à l'intérieur du récipient, et une alimentation est couplée au composant. Durant le fonctionnement du système de résistance à la corrosion, le composant moulé peut être configuré en anode ou en cathode afin de produire une résistance à la corrosion anodique ou cathodique. Sous une forme, l'alimentation est connectée avec un conducteur électrique au récipient, et le composant moulé est mis en couplage électrique avec le récipient. Une purge par gaz inerte peut délivrer un gaz inerte au récipient. Une pompe à vide peut être utilisée pour retirer le gaz du récipient. De plus, un dégazeur d'oxygène peut être utilisé dans certains modes de réalisation.
EP10808599.4A 2009-08-09 2010-08-09 Résistance à la corrosion pour un procédé de lixivation Withdrawn EP2461922A4 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US23245409P 2009-08-09 2009-08-09
PCT/US2010/044917 WO2011019667A1 (fr) 2009-08-09 2010-08-09 Résistance à la corrosion pour un procédé de lixivation

Publications (2)

Publication Number Publication Date
EP2461922A1 true EP2461922A1 (fr) 2012-06-13
EP2461922A4 EP2461922A4 (fr) 2014-04-16

Family

ID=43586418

Family Applications (1)

Application Number Title Priority Date Filing Date
EP10808599.4A Withdrawn EP2461922A4 (fr) 2009-08-09 2010-08-09 Résistance à la corrosion pour un procédé de lixivation

Country Status (3)

Country Link
US (1) US20110048665A1 (fr)
EP (1) EP2461922A4 (fr)
WO (1) WO2011019667A1 (fr)

Cited By (12)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US9579714B1 (en) 2015-12-17 2017-02-28 General Electric Company Method and assembly for forming components having internal passages using a lattice structure
US9968991B2 (en) 2015-12-17 2018-05-15 General Electric Company Method and assembly for forming components having internal passages using a lattice structure
US9987677B2 (en) 2015-12-17 2018-06-05 General Electric Company Method and assembly for forming components having internal passages using a jacketed core
US10046389B2 (en) 2015-12-17 2018-08-14 General Electric Company Method and assembly for forming components having internal passages using a jacketed core
US10099283B2 (en) 2015-12-17 2018-10-16 General Electric Company Method and assembly for forming components having an 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
US10099284B2 (en) 2015-12-17 2018-10-16 General Electric Company Method and assembly for forming components having a catalyzed internal passage defined therein
US10118217B2 (en) 2015-12-17 2018-11-06 General Electric Company Method and assembly for forming components having internal passages using a jacketed core
US10137499B2 (en) 2015-12-17 2018-11-27 General Electric Company Method and assembly for forming components having an internal passage defined therein
US10150158B2 (en) 2015-12-17 2018-12-11 General Electric Company Method and assembly for forming components having internal passages using a jacketed core
US10286450B2 (en) 2016-04-27 2019-05-14 General Electric Company Method and assembly for forming components using a jacketed core
US10335853B2 (en) 2016-04-27 2019-07-02 General Electric Company Method and assembly for forming components using a jacketed core

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US8828214B2 (en) 2010-12-30 2014-09-09 Rolls-Royce Corporation System, method, and apparatus for leaching cast components
CN106018306B (zh) * 2016-08-01 2018-11-13 中国人民解放军军械工程学院 一种氧气吸收率测量装置及测量方法
US11230503B2 (en) 2017-06-27 2022-01-25 General Electric Company Resin for production of porous ceramic stereolithography and methods of its use
CN108057849A (zh) * 2017-11-06 2018-05-22 江苏大学 一种航空用空心叶片中陶瓷型芯的脱除方法及设备
CN107866550A (zh) * 2017-12-21 2018-04-03 西安欧中材料科技有限公司 一种航空发动机空心叶片的陶瓷型芯脱除方法
US11370021B2 (en) 2019-11-22 2022-06-28 Raytheon Technologies Corporation Systems, formulations, and methods for removal of ceramic cores from turbine blades after casting

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WO2006092615A1 (fr) * 2005-03-03 2006-09-08 Cambridge Enterprise Limited Procédé et dispositif électrochimiques pour l’élimination de l’oxygène d’un composé ou d’un métal
US20080087139A1 (en) * 2006-10-16 2008-04-17 Spachner Sheldon A Process for recovering titanium
US20080190777A1 (en) * 2004-09-09 2008-08-14 British Titanium Plc. Electro-Deoxidation Method, Apparatus and Product

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US3030286A (en) * 1958-11-21 1962-04-17 Titanium Metals Corp Descaling titanium and titanium base alloy articles
US3843497A (en) * 1969-06-17 1974-10-22 United Aircraft Corp Electrolytic production of boron
US5679270A (en) * 1994-10-24 1997-10-21 Howmet Research Corporation Method for removing ceramic material from castings using caustic medium with oxygen getter
US6264823B1 (en) * 1998-09-18 2001-07-24 Hoffman Industries International, Ltd. Non-caustic cleaning of conductive and non-conductive bodies
US6203691B1 (en) * 1998-09-18 2001-03-20 Hoffman Industries International, Ltd. Electrolytic cleaning of conductive bodies
US20020157964A1 (en) * 2001-04-25 2002-10-31 Hoffman Industries International, Ltd. System and method for electrolytic cleaning
JP2005522331A (ja) * 2002-04-11 2005-07-28 ロールス−ロイス・コーポレーション セラミック材料を鋳造構成要素から除去する方法及び装置
US20050087321A1 (en) * 2003-10-28 2005-04-28 Thomas Hathaway Apparatus for cleaning metal parts
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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3563711A (en) * 1968-07-18 1971-02-16 Trw Inc Process for removal of siliceous cores from castings
US20080190777A1 (en) * 2004-09-09 2008-08-14 British Titanium Plc. Electro-Deoxidation Method, Apparatus and Product
WO2006092615A1 (fr) * 2005-03-03 2006-09-08 Cambridge Enterprise Limited Procédé et dispositif électrochimiques pour l’élimination de l’oxygène d’un composé ou d’un métal
US20080087139A1 (en) * 2006-10-16 2008-04-17 Spachner Sheldon A Process for recovering titanium

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See also references of WO2011019667A1 *

Cited By (14)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US9579714B1 (en) 2015-12-17 2017-02-28 General Electric Company Method and assembly for forming components having internal passages using a lattice structure
US9968991B2 (en) 2015-12-17 2018-05-15 General Electric Company Method and assembly for forming components having internal passages using a lattice structure
US9975176B2 (en) 2015-12-17 2018-05-22 General Electric Company Method and assembly for forming components having internal passages using a lattice structure
US9987677B2 (en) 2015-12-17 2018-06-05 General Electric Company Method and assembly for forming components having internal passages using a jacketed core
US10046389B2 (en) 2015-12-17 2018-08-14 General Electric Company Method and assembly for forming components having internal passages using a jacketed core
US10099283B2 (en) 2015-12-17 2018-10-16 General Electric Company Method and assembly for forming components having an 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
US10099284B2 (en) 2015-12-17 2018-10-16 General Electric Company Method and assembly for forming components having a catalyzed internal passage defined therein
US10118217B2 (en) 2015-12-17 2018-11-06 General Electric Company Method and assembly for forming components having internal passages using a jacketed core
US10137499B2 (en) 2015-12-17 2018-11-27 General Electric Company Method and assembly for forming components having an internal passage defined therein
US10150158B2 (en) 2015-12-17 2018-12-11 General Electric Company Method and assembly for forming components having internal passages using a jacketed core
US10286450B2 (en) 2016-04-27 2019-05-14 General Electric Company Method and assembly for forming components using a jacketed core
US10335853B2 (en) 2016-04-27 2019-07-02 General Electric Company Method and assembly for forming components using a jacketed core
US10981221B2 (en) 2016-04-27 2021-04-20 General Electric Company Method and assembly for forming components using a jacketed core

Also Published As

Publication number Publication date
US20110048665A1 (en) 2011-03-03
WO2011019667A1 (fr) 2011-02-17
EP2461922A4 (fr) 2014-04-16

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