EP2945762B1 - Procédé de fabrication d'une pièce par fonderie à la cire perdue et refroidissement dirigé - Google Patents

Procédé de fabrication d'une pièce par fonderie à la cire perdue et refroidissement dirigé Download PDF

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Publication number
EP2945762B1
EP2945762B1 EP14703143.9A EP14703143A EP2945762B1 EP 2945762 B1 EP2945762 B1 EP 2945762B1 EP 14703143 A EP14703143 A EP 14703143A EP 2945762 B1 EP2945762 B1 EP 2945762B1
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EP
European Patent Office
Prior art keywords
core
span
shell mould
wax
cooling
Prior art date
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Application number
EP14703143.9A
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German (de)
English (en)
French (fr)
Other versions
EP2945762A1 (fr
Inventor
Yvan Rappart
Christelle BERTHELEMY
Benoît Georges Jocelyn MARIE
David Locatelli
Sébastien Digard Brou de Cuissart
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Safran Aircraft Engines SAS
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Safran Aircraft Engines SAS
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Publication of EP2945762A1 publication Critical patent/EP2945762A1/fr
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D27/00—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting
    • B22D27/04—Influencing the temperature of the metal, e.g. by heating or cooling the mould
    • 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
    • B22C21/00—Flasks; Accessories therefor
    • B22C21/12—Accessories
    • B22C21/14—Accessories for reinforcing or securing moulding materials or cores, e.g. gaggers, chaplets, pins, bars
    • 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
    • B22C9/12—Treating moulds or cores, e.g. drying, hardening
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/22—Moulds for peculiarly-shaped castings
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D27/00—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting
    • B22D27/04—Influencing the temperature of the metal, e.g. by heating or cooling the mould
    • B22D27/045—Directionally solidified castings

Definitions

  • the present invention relates to the field of metal parts, such as turbomachine blades obtained by casting metal in a shell mold and relates to a method of manufacturing these parts with directed solidification of columnar or monocrystalline type.
  • the state of the art also includes documents GB-A-1 377 042 and SU-A1- 606 676 .
  • the process for manufacturing metal parts by lost wax casting comprises a succession of steps recalled below.
  • Models of the parts to be manufactured are first produced in wax or other temporary material. Where appropriate, the models are gathered in a cluster around a central barrel also made of wax.
  • a ceramic material shell is then formed on the models, thus assembled, by successive soaking in slips of suitable composition comprising particles of ceramic materials in suspension in a liquid, alternated with dustings of refractory sand.
  • the wax model is then removed while consolidating the shell mold thus formed by heating.
  • the next step consists in casting a metal alloy, in particular a nickel superalloy, in fusion in the shell mold and then in cooling the parts obtained so as to direct their solidification according to the desired crystalline structure. After solidification, the shell is removed by detaching to extract the parts. Finally, the finishing steps are carried out to remove excess material.
  • the cooling and solidification step is therefore controlled.
  • the solidification of the metal alloy being the passage from the liquid phase to the solid phase, the directed solidification consists in advancing the growth of "seeds" in the bath of molten metal in a given direction, avoiding the appearance of new germs by controlling the thermal gradient and the rate of solidification.
  • Directed solidification can be columnar or monocrystalline. Columnar directed solidification involves orienting all grain boundaries in the same direction, such that they do not contribute to the propagation of cracks. Monocrystalline directed solidification consists in completely eliminating the grain boundaries.
  • the directed, columnar or monocrystalline solidification is carried out in a manner known per se by placing the shell mold, open in its lower part, on a cooled hearth, then by introducing the whole into a heating equipment capable of holding the ceramic mold. at a temperature higher than the liquidus of the alloy to be molded.
  • the metal located in openings made at the bottom of the shell mold solidifies almost instantaneously on contact with the cooled sole and freezes to a limited height of the order of a centimeter on which it has an equilibrium granular structure -axis, that is to say that its solidification over this limited height takes place naturally, without any preferred direction. Above this limited height, the metal remains in the liquid state, due to the imposed external heating.
  • the sole is moved at a controlled speed downwards so as to extract the ceramic mold from the heating device leading to a gradual cooling of the metal which continues to solidify from the lower part of the mold to its upper part.
  • the monocrystalline directed solidification further comprises the interposition between the part to be molded and the cooled sole, either of a baffle or grain selector, or of a monocrystalline seed; the thermal gradient and the rate of solidification are controlled in such a way that no new seeds are created in front of the solidification front. This results in a monocrystalline molded part after cooling.
  • This directed solidification technique is commonly used to produce molded parts, and in particular turbomachine blades, when it is desirable to give the molded parts specific mechanical and physical properties. This is particularly the case when the molded parts are turbomachine blades.
  • weights are used in order to eliminate the porosity defects in end areas of the. parts to be manufactured.
  • excess volumes are provided during the production of wax models, which are placed against the areas of the parts which are liable to exhibit porosity defects after solidification.
  • excess volumes translate into additional volumes inside the shell, and fill with molten metal during casting, in the same way as other parts of the shell.
  • the weights are the reserves of solidified metal which fill the additional volumes in the shell. The porosity defects, when they occur, are then displaced in the weights and are no longer located in the manufactured parts themselves. Then, once the metal has solidified and cooled, the weights are removed during a part finishing operation, for example by machining, by cutting or by grinding.
  • the present invention relates to the manufacture of parts having at least one cavity and the wax model of which is molded around a ceramic core.
  • This core during the casting of the molten metal reserves inside the part the volume corresponding to the desired cavity.
  • the cavities traversed by the cooling fluid are produced in this way.
  • Ceramic cores for turbomachine blades comprise, according to a known method of manufacture, two bearing surfaces or retaining lugs, one at each longitudinal end.
  • the models are prepared in such a way that an embedding or anchoring of the ceramic core is defined at the level of the area of the base of the core in the upper part of the mold. Indeed according to this technique the core and the wax model are mounted foot up and the top down. Thus after the ceramic molding operations, the ceramic shell formed blocks the core in this area.
  • the molten metal fills the imprint released by the wax which has been previously removed. The molten metal occupies the space between the core and the shell wall.
  • the solidification is then carried out by the pulling from top to bottom of the bottom of the furnace on which the shell is placed, the solidification progresses from the starter in which several metal grains solidify then successively in the top of the blade, the blade and the foot.
  • the core is then held at its two ends and is constrained in compression. This results in a deformation of the core by buckling.
  • the core no longer respects its theoretical position and defects may appear on the part: metal wall thicknesses may not be respected, or the core under the effect of the stresses of the two embedments at its two ends perforates the metal wall of dawn by buckling. In both cases the part must be scrapped.
  • the positioning of the embedding at the start of solidification has the drawback of disturbing the incipient solidification front with the risk of generating parasitic grains or disorientation.
  • the subject of the invention is therefore a method of manufacturing a part which overcomes the problems presented above.
  • the process, according to the invention, for manufacturing by lost wax casting of a metal part made of nickel alloy, with a columnar or monocrystalline structure with at least one elongated cavity comprising the following steps of producing a wax model of the part with a ceramic core corresponding to said cavity, the ceramic core having a first support surface at a longitudinal end and a second support surface at the opposite end, the second surface comprising surfaces which are parallel to the direction of cooling propagation and surfaces which are not parallel to the direction of cooling propagation, production of a shell mold around the model, the mold comprising a base and the first bearing surface of the core being on the side of the base of the shell mold, removal of the wax by a dewaxing operation of the shell mold, placing the mold in a furnace, the base being placed on the bottom of the furnace, casting of said molten alloy in the shell mold, Directed solidification of the cast metal by progressive cooling from the hearth in a direction of propagation, the surfaces of the second bearing surface which are not parallel to the direction of propagation of the cooling being initially
  • the core is made integral with the shell mold by an anchoring means between the first bearing surface of the core and the wall of the shell mold, the second bearing surface of the core being retained in the shell mold by a sliding retention means. on the wall of the shell mold, said sliding holding means being a layer of varnish applied, before the production of the shell mold, to the surfaces of the second bearing surface which are parallel to the direction of propagation of the cooling and which are not covered with wax, the surfaces of the second bearing surface which are parallel to the direction of propagation of the cooling, which are not covered with wax and which, after constitution of the shell mold, come into direct contact with the internal wall of the mold, being initially fully coated with the varnish layer, the thickness of the varnish layer being between 3 and 5 hundredths of a millimeter, said layer of varnish being removed during the dewaxing operation of the shell mold, as well as the wax covering the surfaces of the second bearing surface which are not parallel to the direction of propagation of the cooling, so that a free space is created between the second bearing surface of the core and the wall of
  • the solution of the invention makes it possible to avoid the deformation of the core during the progression of the directed solidification because the core is not retained by anchoring at its two ends. It is thus not put into compression by the stresses which would result from the difference in the expansion coefficients between the mold and the core. There is also no risk of generating parasitic grains or of re-bonding defects of the main grain.
  • the solution of the invention also guarantees the position of the core throughout the part manufacturing phase: from the wax model to the casting and solidification of the part.
  • the anchoring means comprises a rod, more particularly of refractory ceramic, alumina for example, passing through the first bearing surface and the wall of the mold.
  • the ceramic rod has a small diameter of the order of a millimeter. The rod passes through the wax model and the core which have been previously drilled to a diameter slightly greater than that of the rod to prevent stresses being generated at this level.
  • the sliding holding means is formed by a space provided between the bearing surface and the wall of the mold, this space is obtained by means of a film of expansion varnish deposited on the surface of the bearing surface at the realization of the model. This is then eliminated during the dewaxing operation. of the mold.
  • a material of the nail varnish type making it possible to obtain thicknesses of a few hundredths of a millimeter per layer.
  • a suitable varnish for this application includes solvents, resin, nitrocellulose and plasticizers.
  • a varnish such as that “Thixotropic base” marketed under the trade name: “Peggy Sage nail varnish all formulas” can be used in the process of the present invention.
  • this film is more precisely interposed between the second bearing surface and the wall of the mold. It is applied, before the formation of the shell mold, on the surfaces of the second bearing surface which are parallel to the direction of the progress of the cooling; that is to say in the case of a bogie, parallel to the pulling direction of the bogie. Its purpose is to prevent, on the one hand, the wall of the mold from sticking to the core in this zone and, on the other hand, to create a free space, after unwinding, of small thickness allowing the longitudinal guiding of the second bearing relative to to the mold and avoiding the mold to exert a stress on the core.
  • the surfaces of the second bearing surface which are not parallel to the axis of the progression of solidification, the drawing axis, are initially covered by a deposit of wax so as to leave, after dewaxing, a space between said surfaces of the second bearing surface and the wall of the mold.
  • This space prevents, during the casting of molten metal, the contact between the wall of the shell and the second scope of the core, and avoids the stressing of the core in this zone during solidification.
  • the thickness of this wax deposit is of the order of a millimeter for parts having a length of 100 to 200 mm, ie approximately 1% of the length of the part.
  • the process allows the simultaneous manufacture of several parts.
  • the models of said parts are in this case gathered in a cluster inside a shell mold.
  • the method applies to the manufacture of at least one metallic part with a columnar structure, a means of germinating the crystalline structure being provided between the shell mold and the bottom of the furnace.
  • the method applies to the manufacture of at least one part with a monocrystalline structure, a grain selector being provided between the seed element and the shell mold.
  • the invention applies in particular to the manufacture of a turbine engine blade, the first range being in the extension of the top of the blade of the blade, the second range being in the extension of the root of the blade.
  • the method advantageously uses a furnace whose sole is movable vertically between a hot zone where the metal is molten and a cold zone for solidification of the metal, the sole itself being cooled.
  • the present invention relates to a method of manufacturing metal parts made of a nickel-based alloy making it possible, through an appropriate directed solidification, to obtain a columnar or monocrystalline crystalline structure.
  • the invention relates more particularly to the manufacture of turbomachine blades such as that shown in figure 1 ; a blade 1 comprises a blade 2, a root 5 allowing it to be attached to a turbine disk, and a top 7 with, where appropriate, a heel. Due to the operating temperatures of the turbomachine, the blades are provided with an internal cooling circuit through which a cooling fluid, generally air, passes. A platform 6 between the root and the blade constitutes a portion of the radially inner wall of the gas stream.
  • the part shown here is a moving blade, but the invention also applies to a distributor or even to any other part having a core. Due to the complexity of the cooling circuit inside the part, it is advantageous to produce it by lost wax casting with a ceramic core to spare the cavities of the cooling circuit.
  • the figures 2 and 3 schematically show a simplified ceramic core used to provide the internal cavities of a turbomachine blade.
  • the core 10 of elongated shape comprises a branch or a plurality of branches 11 separated by spaces 12 to, after the metal has been poured, form the partitions between the cavities; in the example shown, the core comprises two branches 11 separated by a space 12.
  • the core is extended by a bearing surface or tab 14, the function of which is to hold the core during the manufacture of the part but which does not correspond not necessarily to part of the room, once it is completed.
  • the core comprises a second bearing surface 16 for also maintaining the core during the manufacturing steps.
  • This core is placed in a mold for the production of the wax model.
  • the imprint of this mold is the shape of the part to be obtained.
  • Staves 14 and 16 are used for keeping the core in the wax mold.
  • the figure 4 schematically represents this wax model 20 with the core 10 in dotted lines.
  • the model extends at a first end 24 in the extension of the blade so as to cover the bearing surface 14 and at the opposite end 26, at the level of the foot.
  • part 16A of the scope 16 is not covered with wax.
  • This part 16A comprises surfaces parallel to the axis of the core and is coated with a varnish, the function of which is explained below.
  • models are generally assembled in a cluster so as to manufacture several parts simultaneously.
  • the models are for example arranged in a parallel drum around a vertical central cylinder and held by the ends.
  • the lower part is mounted on an element intended to ensure the germination of the crystal structure.
  • the next step is to form a shell mold around the model (s).
  • the assembly is dipped in slurries so as to deposit the refractory ceramic particles in successive layers.
  • the mold is finally consolidated by heating and the wax removed by the dewaxing operation.
  • the first bearing surface 14 is held in the mold 30 by a refractory ceramic rod 40, which passes through it and extends into the wall of the mold 30 while being embedded therein.
  • the rod 40 was put in place before the production of the shell mold, after the model has been drilled at the level of the bearing 14.
  • the hole is slightly larger in diameter than that of the rod so that it is not created. of constraints between the rod and the seat and that the rod ensures correct positioning of the core in the model.
  • the second bearing surface 16, opposite the first, is initially coated with a layer of varnish 17 on the part 16A of the core which is not covered with wax and which, after constitution of the shell mold, comes into direct contact with the internal wall of the core. mold. After dewaxing the mold, as seen on the figure 5 , the layer having disappeared leaves a free space between the bearing surface 16 of the core and the wall of the shell mold. Reference 17 designates this free space left by the layer varnished. This space 17 is thin, 3 to 5 hundredths of a millimeter. It forms a sliding retaining means of the second bearing 16 on the wall of the shell 30.
  • the surfaces - here the horizontal surface 16B - which are not parallel to the axis of the progression of solidification are initially covered by a deposit of wax 18.
  • This deposit of wax leaves a free space after dewaxing, likewise reference 18, which prevents the bearing surface 16 of the core from coming into contact with the wall of the shell when the core expands, thus avoiding stressing the core.
  • the thickness of this wax deposit is of the order of a millimeter for parts having a length of 100 to 200 mm, ie approximately 1% of the length of the part.
  • the core does not run the risk of buckling and the initial wall thicknesses of the part between the wall of the mold and the core are preserved.
  • the figure 5 shows, in section along the part, the shell mold 30 and the core 10 inside the mold with the branches 11, the bearing surfaces 14 and 16.
  • the core is cut along the line VV of the figure 4 .
  • the volume 30 ′ corresponds to the wax of the model or, after solidification of the shell, to the space between the wall of the mold and the core to be filled with the metal.
  • the rod 40 passes through the first bearing 14; it is long enough to be anchored in the walls of the shell mold 30. In this way, the core 10 is positioned inside the shell mold 30.
  • the mold is placed on the bottom of a furnace equipped for directed solidification.
  • a furnace 100 is shown in figure 6 . It shows an enclosure 101 provided with heating elements 102.
  • An orifice 103 for supplying molten metal communicates with a crucible 104 which contains the charge of molten metal and which, by tilting, fills the shell mold 30 placed on the hearth. 105 from the oven.
  • the sole is movable vertically, see the arrow, and is cooled by the circulation of water in a circuit 106 internal to its plate.
  • the mold rests by its base on the cooled sole.
  • the lower part of the mold is open to the sole by means of a germination member.
  • the manufacturing method includes casting molten metal from crucible 104 directly in the mold 30 which is maintained at a temperature sufficient to keep the molten metal, by the heating means 102 of the enclosure 101 and where it fills the voids 30 'between the core 10 and the wall of the mold 30.
  • the metal solidifies forming a crystalline structure that propagates from bottom to top.
  • the sole 105 is continuously cooled and is gradually lowered out of the heated enclosure.
  • a grain selector is interposed between the germination and the solidification as is known per se.
  • the core is held by anchoring the first bearing 14 in the single lower zone for initiating solidification.
  • the core is free to expand differentially in the direction of its length with respect to the shell 30 because at the opposite end of the first bearing surface, the second bearing 16 is guided along the wall of the mold thanks to the free space 17 left by the layer of varnish, removed during dewaxing of the mold.
  • the surfaces of the second bearing 16 - here the horizontal surface 16B - which are not parallel to the axis of the progression of solidification, thanks to the free space 18 provided by the wax deposit, do not come into play. contact with the shell wall. This prevents stress on the core.
  • the thickness of this space corresponding to the wax deposit is of the order of a millimeter for parts having a length of 100 to 200 mm, ie approximately 1% of the length of the part.
  • the mold is broken and the parts are extracted which are sent to the finishing workshop.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
  • Turbine Rotor Nozzle Sealing (AREA)
EP14703143.9A 2013-01-17 2014-01-13 Procédé de fabrication d'une pièce par fonderie à la cire perdue et refroidissement dirigé Active EP2945762B1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
FR1350424A FR3000910B1 (fr) 2013-01-17 2013-01-17 Procede de fabrication d'une piece par fonderie a la cire perdue et refroidissement dirige
PCT/FR2014/050061 WO2014111648A1 (fr) 2013-01-17 2014-01-13 Procédé de fabrication d'une pièce par fonderie a la cire perdue et refroidissement dirigé

Publications (2)

Publication Number Publication Date
EP2945762A1 EP2945762A1 (fr) 2015-11-25
EP2945762B1 true EP2945762B1 (fr) 2021-03-03

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EP14703143.9A Active EP2945762B1 (fr) 2013-01-17 2014-01-13 Procédé de fabrication d'une pièce par fonderie à la cire perdue et refroidissement dirigé

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Country Link
US (1) US10717128B2 (zh)
EP (1) EP2945762B1 (zh)
JP (1) JP6342427B2 (zh)
CN (1) CN104918731B (zh)
BR (1) BR112015016771B1 (zh)
CA (1) CA2897680C (zh)
FR (1) FR3000910B1 (zh)
RU (1) RU2652526C2 (zh)
WO (1) WO2014111648A1 (zh)

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FR3067700B1 (fr) 2017-06-18 2021-02-12 Sogeclair Sa Structure metallique a peau renforcee et procede de fabrication de piece metallique raidie
FR3070285B1 (fr) * 2017-08-25 2021-01-22 Safran Aircraft Engines Noyau pour la fafrication d'une aube de turbomachine
CN109570444A (zh) * 2018-09-30 2019-04-05 鹰普航空零部件（无锡）有限公司 一种复杂型腔不锈钢铸件的成形方法
CN109622883B (zh) * 2019-01-08 2021-07-23 中国航发动力股份有限公司 一种陶瓷型芯自由端蜡帽制造方法
FR3100143B1 (fr) 2019-08-30 2021-11-12 Safran Procédé amélioré de fabrication d’un noyau céramique pour la fabrication d’aubes de turbomachine
CN115069978B (zh) * 2021-03-16 2024-05-28 中国航发商用航空发动机有限责任公司 燃烧室挡溅盘铸造系统及铸造方法
CN113976824B (zh) * 2021-10-20 2023-09-15 中国航发沈阳黎明航空发动机有限责任公司 一种防止联体单晶导向叶片型芯自由端产生杂晶的方法
CN115121768B (zh) * 2022-04-26 2024-04-05 湘潭大学 型壳结构及其制备方法和热裂倾向性判定方法

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BR112015016771A2 (pt) 2017-07-11
BR112015016771B1 (pt) 2020-01-28
JP2016503729A (ja) 2016-02-08
JP6342427B2 (ja) 2018-06-13
CN104918731B (zh) 2019-12-27
EP2945762A1 (fr) 2015-11-25
RU2652526C2 (ru) 2018-04-26
US10717128B2 (en) 2020-07-21
CA2897680A1 (fr) 2014-07-24
WO2014111648A1 (fr) 2014-07-24
RU2015128268A (ru) 2017-02-21
US20150352634A1 (en) 2015-12-10
CN104918731A (zh) 2015-09-16
CA2897680C (fr) 2021-03-23
FR3000910A1 (fr) 2014-07-18
FR3000910B1 (fr) 2015-05-01

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