EP2938448B1 - Noyau de moulage de précision à modèle perdu contenant de la mullite - Google Patents

Noyau de moulage de précision à modèle perdu contenant de la mullite Download PDF

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Publication number
EP2938448B1
EP2938448B1 EP13868294.3A EP13868294A EP2938448B1 EP 2938448 B1 EP2938448 B1 EP 2938448B1 EP 13868294 A EP13868294 A EP 13868294A EP 2938448 B1 EP2938448 B1 EP 2938448B1
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EP
European Patent Office
Prior art keywords
mullite
core body
investment casting
core
recited
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EP13868294.3A
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German (de)
English (en)
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EP2938448A1 (fr
EP2938448A4 (fr
Inventor
Mario P. Bochiechio
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RTX Corp
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United Technologies Corp
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C1/00—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds
    • 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

Definitions

  • This disclosure relates to investment casting and, more particularly, to investment casting cores.
  • Investment casting is known and used to cast metallic components with relatively complex geometries.
  • gas turbine engine components such as airfoils that have internal passages
  • a core is provided which represents a positive projection of negative features that are to be formed in the casting process.
  • a wax material is then provided around the core in the shape of the component to be cast.
  • a shell is then formed around the wax and the wax is removed to form a cavity between the core and the surrounding shell into which molten metal is poured to form the shape of the component. After solidification of the metal, the core is removed using known techniques to provide the cast component.
  • US 2005/070651 discloses an investment casting core comprising a mullite-containing core body.
  • An investment casting core includes a mullite-containing core body and characterised by the investment casting core comprising a metallic core body joined to the mullite-containing core body, wherein the coefficient of thermal expansion of the mullite-containing core body is within 2% of the coefficient of thermal expansion of the metallic core body.
  • the mullite-containing core body has, by weight, 40% or greater of mullite.
  • the mullite-containing core body has, by weight, 40-90% of mullite.
  • the mullite-containing core body has a material selected from the group consisting of alumina, silica, magnesia, yttria, calcia, zirconium silicate and combinations thereof.
  • the mullite-containing core body has, by weight, 40-90% of mullite and 60-5% of silica.
  • the mullite-containing core body has a material selected from the group consisting of magnesia, yttria, calcia and combinations thereof.
  • the mullite-containing core body has zirconium silicate.
  • the metallic core body is selected from the group consisting of molybdenum, tungsten, tantalum, rhenium, niobium and combinations thereof.
  • the mullite-containing core body has, by weight, 80-90% mullite, 15-5% silica, 2.5- 10% alumina, 0-2.5% zircon, 0-5% of one or more of: calcia, magnesia and yttria.
  • the mullite-containing core body has a multi-modal or bi-modal grain size distribution.
  • a method of making an investment casting core includes: providing a mullite-containing powder; forming the mullite-containing powder into a green body; and sintering the green body to form a mullite-containing core body; and characterised by joining the mullite-containing core body to a metallic core body, wherein the coefficient of thermal expansion of the mullite-containing core body has a coefficient of thermal expansion within 2% of the coefficient of thermal expansion of the metallic core body.
  • a further non-limiting embodiment of any of the foregoing examples includes providing the mullite-containing powder in a blend with a binder, and the forming includes molding the blend into the green body.
  • the mullite-containing powder has at least a bi-modal particle size distribution of mullite particles.
  • the mullite-containing powder has a material selected from alumina, silica, magnesia, yttria, calcia, zirconium silicate and combinations thereof in a powder with at least a bi-modal particle size distribution.
  • a further non-limiting embodiment of any of the foregoing examples includes selecting a composition of the mullite-containing powder to obtain a coefficient of thermal expansion in the mullite-containing core body that matches a coefficient of thermal expansion of the metallic core body.
  • a method of investment casting according to an exemplary aspect of the present disclosure includes: casting a metallic component at least partially around an investment casting core that has a mullite-containing core body; and characterised by the investment casting core further comprising a metallic core body joined to the mullite-containing core body, wherein the coefficient of thermal expansion of the mullite-containing core body is within 2% of the coefficient of thermal expansion of the metallic core.
  • a further non-limiting embodiment of any of the foregoing examples includes the mullite-containing core body that has a material selected from the group consisting of alumina, silica, magnesia, yttria, calcia, zirconium silicate and combinations thereof.
  • Figure 1 schematically illustrates selected portions of an example investment casting core 20 (hereafter "core 20").
  • core 20 is shown schematically for purposes of description and the actual geometry will depend on the design features of the cast component.
  • the cast component can be an airfoil for a gas turbine engine, however, the examples herein are also applicable to other engine components or non-engine components.
  • the core 20 includes a mullite-containing core body 22.
  • a "body” is a main or central foundational part, distinct from subordinate features, such as coatings or the like that are supported by the underlying body and depend primarily on the shape of the underlying body for their own shape.
  • the mechanical characteristics of a core influence the quality of the investment casting process and component.
  • solidification of the metallic material exerts a force on the core. If the Young's Modulus is to high, the core will resist the solidification forces and may undesirably cause high internal stresses in the cast component or "hot tearing" of the component.
  • the mullite-containing core body 22 has a composition that provides "crushability" of the core 20 during investment casting. That is, the core 20 is tailored to "crush" under the solidification forces to reduce internal stresses and hot tearing.
  • the mullite-containing core body 22 has a composition that has, by weight, 40% or greater of mullite. In a further example, the mullite-containing core body 22 has, by weight, 40-90% of mullite.
  • additional materials are used with the mullite to adjust a coefficient of thermal expansion ("CTE") of the mullite-containing core body 22 and/or as processing aids.
  • the mullite-containing core body 22 has one or more materials selected from: alumina, silica, magnesia, yttria, calcia, zirconium silicate or combinations thereof.
  • the alumina, silica, magnesia, yttria and calcia may be added to adjust the CTE.
  • the yttria, calcia and zirconium silicate may be added as processing aids (yttria and calcia) to facilitate sintering when making the mullite-containing core body 22 or as grain growth inhibitors (zirconium silicate).
  • the mullite-containing core body 22 has, by weight, 40-90% of mullite and 60 - 5 % silica.
  • the mullite-containing core body can also include up to 25% by weight of alumina, up to 5% by weight of magnesia, up to 5% by weight of yttria, up to 5% by weight of calcia and up to 10% by weight of zirconium silicate.
  • the mullite-containing core body 22 can have a grain size that has a grain size distribution that is equal to or approximately equal to a powder size distribution, such as a bi-modal or multi-modal particle size distribution as discussed below. This, the grain size distribution can be multi-modal or bi-modal.
  • the core 20 has a shape that corresponds to negative features that are to be formed in the investment cast component, such as gas turbine engine airfoils.
  • the illustrated core 20 has elongated limbs 24 and branches 26 that extend off of the limbs 24. It is to be understood, however, that the core 20 may alternatively have different geometries than shown, depending upon the features that are to be formed in the investment cast component.
  • the core 20 can be a multi-material core that, in addition to the mullite-containing core body 22, also has a metallic core body 28 that is joined with the mullite-containing core body 22.
  • the metallic core body 28 is a refractory metal core.
  • the refractory metal is selected from molybdenum, tungsten, tantalum, rhenium, niobium and combinations thereof.
  • the metallic core body 28 can be joined to the mullite-containing core body 22 using an adhesive material.
  • the adhesive material is applied the joining surface of the mullite-containing core body 22, the metallic core body 28 or both in the form of slurry, such as a colloidal silica-based slurry.
  • the colloidal silica based adhesive slurry will be comprised of materials of similar composition to the main core body: mullite, alumina, zirconia silicate to act as filler material as well as to ensure compatibility with the main body core.
  • the colloidal silica serves as a binder adhesive to secure the mullite-containing core body 22 and the metallic core body 28 together.
  • other types of adhesives and ceramic materials could be used including adhesive systems based upon, ethyl silicate, sodium silicate, collidial alumina, colloidal yttria, colloidal zirconia.
  • the composition of the mullite-containing core body 22 can be tailored with regard to CTE to closely match the CTE of the metallic core body 28.
  • mullite provides a relatively close match in CTE.
  • the mullite composition can be modified with the alumina, silica, magnesia or combinations thereof to modify the CTE of the mullite-containing core body 22 in accordance with the CTE of the selected refractory metal of the metallic core body 28.
  • the CTE of the mullite-containing core body 22 is within about 2% of the CTE of the metallic core body 28.
  • Figure 2 illustrates an example method 30 of making the investment casting core 20.
  • the method 30 includes steps 32, 34 and 36.
  • Step 32 includes providing a mullite-containing powder
  • step 34 includes forming the mullite-containing powder into a green body
  • step 36 includes sintering the green body to form the mullite-containing core body 22.
  • step 32 includes providing the mullite-containing powder in a blend with a binder and then in step 34 molding the blend to form the green body.
  • the binder can be a thermoplastic material, a wax material or a wax material with viscosity modifiers, such as stearate.
  • the blend includes approximately 10-20% by weight of the binder material and a remainder of the mullite-containing powder.
  • the composition of the mullite-containing powder can be tailored according to the desired composition of the mullite-containing core body 22. That is, the mullite-containing powder can include mullite powder and powders of any or all of the other above-described materials of alumina, silica, magnesia, yttria, calcia and zirconium silicate.
  • the mullite-containing powder has at least a bi-modal particle size distribution.
  • the bi-modal distribution provides a blend of coarse and fine particles that facilitate forming the green body with relatively large sections and also with relatively thin sections. That is, the multi-modal particle size distribution facilitates filling a mold to form a relatively complex green body shape.
  • Powders of the added materials in addition to the mullite can also include a multi-modal particle size distribution for similar purposes. Given this description, one of ordinary skill in the art will be able to determine a bimodal or multi-modal distribution to meet their particular needs. As examples, multi-modal distributions are described in " Fitting Bimodal Particle Size Distribution Curves" J. M. Dallavalle et. al., Ind. Eng. Chem., 1951, 43 (6), pp 1377-1380 , and Reed, James, Introduction to the principles of ceramic processing, New York, A Wiley-Interscience publication, 1995 .
  • a method 40 of investment casting can be implemented after forming the mullite-containing core body 22.
  • the method 40 includes casting a metallic component at least partially around the investment casting core 20 that has the mullite-containing core body 22.
  • the details of investment casting, aside from the core 20 and mullite-containing core body 22, are generally known and therefore will not be described in further detail herein.
  • the methods 30 and 40 need not be conducted together. That is, the methods 30 and 40 can be mutually independent.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
  • Mold Materials And Core Materials (AREA)

Claims (14)

  1. Noyau de moulage de précision à modèle perdu (20) comprenant :
    un corps de noyau contenant de la mullite (22) ; et caractérisé par le noyau de moulage de précision à modèle perdu comprenant un corps de noyau métallique (28) joint au corps de noyau contenant de la mullite, dans lequel le coefficient d'expansion thermique du corps de noyau contenant de la mullite (22) ne dépasse pas 2 % du coefficient d'expansion thermique du corps de noyau métallique.
  2. Noyau de moulage de précision à modèle perdu selon la revendication 1, dans lequel le corps de noyau contenant de la mullite présente en poids 40 % ou plus de mullite, de préférence dans lequel le corps de noyau contenant de la mullite présente, en poids, 40 à 90 % de mullite.
  3. Noyau de moulage de précision à modèle perdu selon la revendication 1 ou 2, dans lequel le corps de noyau contenant de la mullite présente un matériau sélectionné dans le groupe composé d'alumine, de silice, de magnésie, d'yttrium, de calcium, de silicate de zirconium et de combinaisons de ceux-ci .
  4. Noyau de moulage de précision à modèle perdu selon une quelconque revendication précédente, dans lequel le corps de noyau contenant de la mullite présente en poids 40 à 90 % de mullite et 60 à 5 % de silice.
  5. Noyau de moulage de précision à modèle perdu selon une quelconque revendication précédente, dans lequel le corps de noyau contenant de la mullite présente un matériau sélectionné dans le groupe composé de magnésie, d'yttrium, de calcium et de combinaisons de ceux-ci, ou dans lequel le corps de noyau contenant de la mullite présente du silicate de zirconium.
  6. Noyau de moulage de précision à modèle perdu selon une quelconque revendication précédente, dans lequel le corps de noyau métallique est sélectionné dans le groupe composé de molybdène, de tungstène, de tantale, de rhénium, de niobium et de combinaisons de ceux-ci.
  7. Noyau de moulage de précision à modèle perdu selon une quelconque revendication précédente, dans lequel le corps de noyau contenant de la mullite présente en poids 80 à 90 % de mullite, 15 à 5 % de silice, 2,5 à 10 % d'alumine, 0 à 2,5 % de zircon, 0 à 5 % d'un ou de plusieurs de : calcium, magnésie et yttrium.
  8. Noyau de moulage de précision à modèle perdu selon une quelconque revendication précédente, dans lequel le corps de noyau contenant de la mullite présente une distribution granulométrique multimodale ou bimodale.
  9. Procédé de fabrication d'un noyau de moulage de précision à modèle perdu (20), le procédé comprenant :
    la fourniture d'une poudre contenant de la mullite ;
    la formation de la poudre contenant de la mullite dans un corps vert ; et
    le frittage du corps vert pour former un corps de noyau contenant de la mullite (22) ;
    et caractérisé par la jonction du corps de noyau contenant de la mullite à un corps de noyau métallique (28), dans lequel le coefficient d'expansion thermique du corps de noyau contenant de la mullite (22) présente un coefficient d'expansion thermique qui ne dépasse pas 2 % du coefficient d'expansion thermique du corps de noyau métallique.
  10. Procédé selon la revendication 9, incluant la fourniture de la poudre contenant de la mullite dans un mélange avec un liant, et la formation inclut le moulage du mélange dans le corps vert, et/ou dans lequel la poudre contenant de la mullite présente au moins une distribution granulométrique bimodale de particules de mullite.
  11. Procédé selon la revendication 9 ou 10, dans lequel la poudre contenant de la mullite présente un matériau sélectionné parmi l'alumine, la silice, la magnésie, l'yttrium, le calcium, le silicate de zirconium et des combinaisons de ceux-ci dans une poudre avec au moins une distribution granulométrique bimodale.
  12. Procédé selon l'une quelconque des revendications 9 à 11, comprenant en outre la sélection d'une composition de la poudre contenant de la mullite pour obtenir un coefficient d'expansion thermique dans le corps de noyau contenant de la mullite qui correspond à un coefficient d'expansion thermique du corps de noyau métallique.
  13. Procédé de moulage de précision à modèle perdu, le procédé comprenant :
    le moulage d'un composant métallique au moins partiellement autour d'un noyau de moulage de précision à modèle perdu (20) qui présente un corps de noyau contenant de la mullite (22) ; et caractérisé par le noyau de moulage de précision à modèle perdu comprenant en outre un corps de noyau métallique (28) joint au corps de noyau contenant de la mullite, dans lequel le coefficient d'expansion thermique du corps de noyau contenant de mullite (22) ne dépasse pas 2 % du coefficient d'expansion thermique du noyau métallique.
  14. Procédé selon la revendication 13, dans lequel le corps de noyau contenant de la mullite présente un matériau sélectionné dans le groupe composé d'alumine, de silice, de magnésie, d'yttrium, de calcium, de silicate de zirconium et de combinaisons de ceux-ci.
EP13868294.3A 2012-12-28 2013-12-12 Noyau de moulage de précision à modèle perdu contenant de la mullite Active EP2938448B1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US13/729,077 US20140182809A1 (en) 2012-12-28 2012-12-28 Mullite-containing investment casting core
PCT/US2013/074555 WO2014105436A1 (fr) 2012-12-28 2013-12-12 Noyau de moulage de précision à modèle perdu contenant de la mullite

Publications (3)

Publication Number Publication Date
EP2938448A1 EP2938448A1 (fr) 2015-11-04
EP2938448A4 EP2938448A4 (fr) 2016-08-31
EP2938448B1 true EP2938448B1 (fr) 2018-07-04

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EP13868294.3A Active EP2938448B1 (fr) 2012-12-28 2013-12-12 Noyau de moulage de précision à modèle perdu contenant de la mullite

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US (1) US20140182809A1 (fr)
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Publication number Priority date Publication date Assignee Title
US9950358B2 (en) 2015-11-19 2018-04-24 General Electric Company Compositions for cores used in investment casting

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US4164424A (en) * 1977-10-06 1979-08-14 General Electric Company Alumina core having a high degree of porosity and crushability characteristics
US4837187A (en) * 1987-06-04 1989-06-06 Howmet Corporation Alumina-based core containing yttria
US4767479A (en) * 1987-09-21 1988-08-30 United Technologies Corporation Method for bonding ceramic casting cores
JP2663392B2 (ja) * 1992-06-19 1997-10-15 工業技術院長 チタン及びその合金の鋳造用中子
US5612393A (en) * 1993-12-24 1997-03-18 Nissan Motor Co., Ltd. Casting core composition
US6637500B2 (en) * 2001-10-24 2003-10-28 United Technologies Corporation Cores for use in precision investment casting
US7287573B2 (en) * 2003-09-30 2007-10-30 General Electric Company Silicone binders for investment casting
US7207374B2 (en) * 2004-10-26 2007-04-24 United Technologies Corporation Non-oxidizable coating
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US8100165B2 (en) * 2008-11-17 2012-01-24 United Technologies Corporation Investment casting cores and methods
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Also Published As

Publication number Publication date
EP2938448A1 (fr) 2015-11-04
EP2938448A4 (fr) 2016-08-31
WO2014105436A1 (fr) 2014-07-03
US20140182809A1 (en) 2014-07-03

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