EP3119544A1

EP3119544A1 - Lined centrifugal mold with controlled thermal inertia

Info

Publication number: EP3119544A1
Application number: EP15706869.3A
Authority: EP
Inventors: Guillaume Martin; Serge Fargeas; Marc SOISSON; Valéry PIATON
Original assignee: Safran Aircraft Engines SAS
Current assignee: Safran Aircraft Engines SAS
Priority date: 2014-01-31
Filing date: 2015-01-28
Publication date: 2017-01-25
Anticipated expiration: 2035-01-28
Also published as: FR3017062A1; US9764382B2; EP3119544B1; US20160339512A1; WO2015114250A1; FR3017062B1

Abstract

The invention relates to an assembly including a mold (4), suitable for casting a molten metal alloy therein, and to said metal alloy cast therein. The alloy is TiAl. The mold is rotatable and includes receiving recesses (135) made of steel, metal alloy, and/or ceramic. The mold has a surface heat capacity less than that of the cast metal alloy at a plurality of section planes that each pass through the mold and the cast metal alloy.

Description

Centrifugal mold with controlled thermal inertia

The present invention relates to the casting by centrifugal casting of metal parts in particular turbomachine blades, and in particular turbojet turbine blades or airplane turboprop. Are

specifically concerned a mold, its use, and the assembly comprising the mold and the molten metal alloy which is cast therein.

It is known to make turbomachine blades by machining a blank obtained from a foundry. The blank is typically a bar, that is, a block of generally elongated material.

One of the techniques for obtaining the blank is the lost-wax casting with casting of the metal alloy in a preheated ceramic mold, centrifuged or not. In this case the blank can be closer to the machined final geometry. This mold is for single use. In addition, chemical interactions between the molten alloy and the ceramic can generate defects on the surface of the blank,

Another solution is to cast bars in a centrifuged metal permanent mold. This appears promising, in particular for manufacturing TiAl-based metal alloy blades, more particularly for β / α solidification.

However, these bars are segregated, especially aluminum, and the chemical heterogeneity can locally lead to non-conforming properties vis-à-vis the expected requirements.

It is therefore important to control (limit / suppress) these segregations.

A problem to be solved concerns the control of the cooling rate of the molten metal alloy after casting to promote the production of a homogeneous level of aluminum in the bar, and thus of a controlled microstructure. It should be noted that the problem can therefore arise with metal alloys containing aluminum, other than the aforementioned TiAI. Bars cast in centrifugal foundries are currently mainly intended for remelting. Segregations are then not a problem since they are then rehomogenized during remelting. If it is desired to directly use these cast bars, the simplest solution would be to heat the molds to restrict the thermal gradients and thus limit segregation. However, centrifugal foundry plants do not lend themselves or little to the preheating of metal molds. This solution is therefore imperfect.

Thus, the technical solutions described below result from an effort to understand and explain the phenomena involved in the solidification of the alloy bars, in particular TiAl.

According to a first definition, the solution proposed here is to recommend using a set comprising:

a mold adapted to cast a molten metal alloy, and said metal alloy which is cast in the mold,

characterized in that

the metal alloy is TiAl,

the mold is rotatable for centrifugal casting and comprises reception housings, made of steel, metal alloy and / or ceramic, adapted to be cast in a centrifuged manner into said molten TiAl alloy metal, and

- At the location of several cutting planes each passing through the mold and the cast metal alloy, the mold has a surface thermal capacity lower than that of the cast metal alloy.

To promote control of cooling,

it is furthermore proposed that the mold comprises:

several reception housings extend radially around the axis of rotation of the mold,

and at least one hollow exoskeleton accommodating folders defining said housings together, with as additional specificities: - that the exoskeleton (s) are open,

- or that an empty space exists peripherally between each folder and the surrounding exoskeleton,

or that an alveolar structure extends peripherally between each liner and the exoskeleton.

By providing such a mold inserts, we will in particular be able to:

- propose thin jacket walls with low thermal inertia,

and / or propose walls of jackets of variable thickness with controlled thermal inertia,

to tend towards an effective controlled cooling of the cast alloy,

- ensure the mechanical strength of the assembly mainly via the outer structure (the (s) exoskeleton (s)).

It is furthermore recommended that the jackets have, with respect to the molten metal alloy, a predominant thermal behavior with respect to that of the exoskeleton (s).

Regarding the mold itself, it is provided, in addition to its rotational character, adapted to a centrifugal casting, with thus shirts defining all of said housings and which are housed in at least one hollow exoskeleton, the fact that the exoskeleton (s) is / are made of mild steel, steel or metal alloys and the sheaths are made of mild steel, steel or metal and / or ceramic alloys.

Thus (and this is therefore valid at the location of each of several remote cutting planes along any shirt), it is recommended:

- that together, a jacket and the exoskeleton (or part of exoskeleton) surrounding it have a first surface heat capacity,

the molten alloy poured into this jacket has a second surface thermal capacity,

and that the torque formed by each jacket and its exoskeleton, on the one hand, and the alloy, on the other hand, is chosen so that the ratio between the first and second surface thermal capacities is less than 1. Thus, the present invention will overcome at least some of the aforementioned drawbacks simply, efficiently and economically.

In the case of a TiAl block, maintaining the aforementioned ratio makes it possible to obtain aluminum segregations between the periphery and the core of the order of 0.2% by mass.

Also note that using a solution with shirts and exoskeleton (s), we will be able to dissociate:

- Some physical characteristics of the exoskeleton (s), which (s) which (s) may participate in the dissipation more or less rapid heat born of casting, while taking a significant part of the efforts during centrifugation (it is advisable a held to withstand a centrifugal acceleration of more than 10 g),

- With respect to the physical characteristics of the shirts which may therefore be thin and / or in a different material from that of the / exoskeletons.

It will also be possible to work in a more appropriate way the forms (especially interior) of the shirts, without necessarily working in the same manner those of the exoskeleton (s).

It should also be noted that providing a cellular structure extending peripherally between each liner and the surrounding exoskeleton will, by virtue of its box structure, make it possible to promote thermal control and / or mechanical strength, as permitted by a realization of the louvre exoskeleton: the thermal inertia will then be lower than if the same (s) exoskeleton (s) were (in) t solid wall (s).

Same consideration if, as advised, one foresees:

that the exoskeleton (s) is (are) of steel and that the jackets are made of a metallic material of lower thermal inertia, or of refractory material (s), and / or - Individually the shirts have a peripheral wall; between two opposite free ends, a length in the radial direction in which each extends and, on this length,

a central casting duct for the alloy having an average cross-section and

an average peripheral wall thickness of less than 1/8, and preferably 1/10, of one of the dimensions of said section

Moreover, it is provided, independently or in combination:

- that the exoskeleton (s) can (s) be hung,

- that a space can exist peripherally between each folder and the surrounding exoskeleton,

- A honeycomb structure extends peripherally between each shirt and the surrounding exoskeleton.

This will be beneficial for controlling thermal gradients, controlling solidification and thus controlling segregation.

With metal folders, it will promote a limitation of the contamination of the material of the blank by that of the mold.

In addition, it will tend to the above using a rotary mold as above, with housing, steel, metal alloy and / or ceramic, for receiving a metal alloy TiAI, and respecting the ratio of aforementioned surface thermal capacities.

Other advantages and characteristics of the invention will appear on reading the following description given by way of nonlimiting example and with reference to the appended drawings in which:

FIG. 1 is a diagrammatic front view of a solid bar of the prior art, in which at least one turbomachine turbine blade is intended to be machined,

FIG. 2 is a schematic view of a mold of the prior art, FIG. 3 is a diagrammatic view from above of a shirt and exoskeleton mold in which bars having less segregation will be molded;

FIGS. 4,5,6,7,8,9,10,11,12,13,14,15,16,17,18,19,20,21 schematize folders and exoskeletons according to various embodiments, in front view (FIGS. 4, 6), longitudinal schematic sections (one of the radial axes B; FIGS. 12, 14, 17, 18, 20) or transverse section (FIG. 7, section VII-VII, FIG. XI, Figures 15,16,19,21), viewed from the side (Figure 5-view V- and 8,9,10,); FIG. 13 being a detail of an alternative embodiment of zones identical to that referenced XIII,

FIG. 22 is a graph which shows test results obtained on several TiAl castings in steel molds of different shapes and thicknesses, with the abscissa ratio (Ci / Ci ') and the ordinate the segregation rate found in FIG. the cast alloy (by weight of Al),

and FIG. 23 schematizes the locations of the four square sections (54, 56, 58 and 61 mm shown in FIG. 22) chosen to characterize a single mold of variable section.

Figure 1 shows a rod 11 made of metal foundry and in which are intended to be machined (s) at least one, here two turbine blades 12 of a turbomachine.

The bar 11 may have a cylindrical shape and is full. It is obtained by casting a metal alloy in a mold.

FIG. 2 shows a conventional device 10 for manufacturing bars or blanks 11, by successive melting and casting operations.

The device 10 comprises a closed and sealed enclosure 20 in which a partial vacuum is applied. An ingot 16 of metal alloy, in this case based on TiAl, is first melted in a crucible 14. In melting, it is poured into a permanent metal mold 13.

The mold 13 makes it possible to cast the alloy by centrifugation, in order to obtain bars 11. For this, it is rotated about an axis A vertical, preferably via a motor 18. The mold 13 comprises a plurality of recesses or cavities 17, which extend radially (axes B1, B2, FIGS. preferably regularly spaced angularly about the axis A which is here vertical. The casting alloy, brought to the center of the mold, is distributed to the cavities.

After cooling, the mold 13 is disassembled and the molded bars 11 are extracted. The thicknesses of the mold can lead to a high thermal inertia and create significant thermal gradients during the cooling of the cast metal, generators of radial segregation including aluminum from the center to the periphery of the bars. The aluminum segregation is reflected during the solidification of the alloy by progressive depletion of the residual liquid during the growth of dendrites from the walls of the mold. The parts from the bars 11 may therefore have differences in microstructures.

Furthermore, in case of wear, it is necessary to change the part of the mold surrounding the radial housing 17 concerned.

The invention makes it possible to provide a solution to the cited problem of segregations and, if necessary, to meet the requirements of resistance to centrifugal forces and rapid and frequent change of at least part of the mold.

To this end, it is expected that the mold 13 retained is designed, then the centrifugal casting blocks 11 made, so that at the location of several cutting planes (such as P1, P2 Figure 4, P3, P4 figure 14, P5, P6 FIG. 18) passing through the mold and the molten metal alloy 11 contained (in contact with it, see FIG. 14), this mold has a surface thermal capacity (Ci) lower than that (Ci ') of the molten metal alloy content. Although this is not limiting, the illustrated sectional planes are perpendicular to the B axis.

Thus, either at the location for example of the sectional plane P1 of the figure

4: Cl = 1. IF. cl (kj, K ^1, m ¹ ), the surface thermal capacity of the mold (here, therefore, of the jacket 135 surrounded by the exoskeleton 137), and Cl = pl '. IF . C1 (kj, K ^_1, ^m_1 ), the surface heat capacity of the molten metal alloy 11 contained, with:

p1 and p1 ', the densities respectively of the material constituting the mold, and of this metal alloy,

S1 and S1 ', respectively the sections of the mold (jacket 135 surrounded by the exoskeleton 137), and of this metal alloy, and

c1 and c1 'the specific heats of the mold (jacket 135 surrounded by the exoskeleton 137), and the metal alloy,

it is provided :

- that C1 / C1 '<1

and that this is also checked in the same way at other cutting planes, such as those referenced P2, P3, P4, P5, P6.

The limit value (surface thermal capacity of the mold / surface thermal capacity of the metal alloy cast on contact <1) was established from results obtained in particular on several TiAl castings, in steel molds of different shapes and thicknesses. . For each bar, the segregation was obtained by making precise measurements of the aluminum content (uncertainty less than 0.06% by weight of Al - wt Al) at the surface and in the center of the bar. The measured difference defines radial macrosegregation. The results are shown in FIG. 22, where the shapes of the tested liners and their conformations in radial vertical section with respect to the example of the axes B1 or B2 are shown in Figure 2 (full peripheral wall, relative dimensions, etc.). specified dimensional values. The square sections (54, 56, 58 and 61 mm) are from a single mold of variable section (Figure 23); radial segregation was measured for these four slices and compared to the specific ratio of each section.

The three sections with a ratio less than 1 (to within 10%) have radial periphery-core segregations in aluminum less than or equal to 0.2% wt (to within 10%). On the other hand, all sections giving a ratio greater than 1 have greater aluminum segregation, all the more important as the ratio is large.

Figures 3 to 21 show embodiments of a mold 130 according to the invention, it being noted that Figures 5 and following schematize variants. As to all the functional means of which these mold embodiments are preferably provided, they have not been illustrated or systematically incorporated in all the variants described hereinafter. The particularities of these embodiments can be combined and applied from one mode to another.

The mold 130 differs from the mold 13 in the realization of some of its structural means.

Around the central block 131, by the bent inner conduits 132 which the alloy is caused to distribute radially around the central vertical axis A, are regularly spaced shirts 135 (or for example 135a, 135b Figure 4). The ducts 132 open respectively into radial ducts 133 which receive the alloy through an opening 133a and each extend inside one of the jackets, in a radial direction B. The opening 133a of each jacket is thus located in the radially inner end portion 134a of the duct concerned.

The shirts, which are thus hollow, are arranged in at least one exoskeleton 137, and preferably in as many exoskeletons as there are shirts, each exoskeleton then containing a jacket 135 defining one of said housings.

The exoskeleton (s) retain the jackets with respect to the centrifugal forces generated by the rotation of the mold.

4, the central axis A of rotation of the mold is vertical and both shirts 135 and exoskeletons 137 each extend along a horizontal longitudinal axis (axis B).

At its radially outer end (end portion 134b), each duct 133 has a solid bottom 135c. Similarly, each exoskeleton 137 has, at its radially inner end, an opening 137a (see, for example, FIGS. 1, 2, 17) through which, for example, a liner 1 can pass and, at its radially outer end, a bottom 137b that can participate in the radial retention of the shirt.

Figure 6, we note 139a, 139b fixations, here removable, established between the illustrated shirt, here 135a, and the exoskeleton, here 137a, which surrounds it, so as to allow a replacement of the sleeve. Screwed fasteners may be suitable.

It can also be seen, see FIG. 4, that removable fasteners, such as 141a, 141b, are provided between each jacket (and / or the surrounding exoskeleton, references 142a, 142b) and the central block 131.

Thus it will be possible to separate the shirts from the exoskeletons and the central block 131, in particular to replace these shirts. Again, screwed fasteners may be suitable.

The removable fasteners established between shirts and exoskeleton (s) and / or between the central block 131 and shirts and / or exoskeleton (s) may form thermal break zones.

In a preferred embodiment, the exoskeleton (s) will be made of steel (such as mild steel) and the jackets will be made of a metallic material of lower thermal inertia, or of refractory material (s).

Figure 7, the peripheral wall is referenced 135d and there is seen in the center, the molded bar (blank) 110 from the casting.

FIG. 8 illustrates a solution in which the schematized exoskeleton 137a is provided with a movable gate 143a which, in the open position, releases an opening 145 enabling the liner in question to be passed through, here 135a. Hinges 147a, may facilitate the operation of each mobile door.

In Figures 4 to 8, it will still be noted that the exoskeletons are open. They are thus like cages somehow meshed.

To promote a low thermal inertia, it is provided here that a space 155 exists peripherally (around the axis B) between each jacket, such as 135a, and the exoskeleton, such as 137a, which surrounds it.

Centering means 157 position, in a fixed manner during the centrifugation, the liner in question relative to the exoskeleton, for casting (see FIG. 5).

Figures 9,10 the shirts are individually formed of several shells, such as 150a, 150b.

These shells open and close along a surface (here joint plane 152) which is generally transverse to the axis (A) around which the mold rotates.

In addition, a separable attachment 153, such as a latch, is established between the shells for, once the shells are separated, to be able to pull the bar 110 from the inside of the liner, here 135a, considered, through the opening 154 released.

In the solution of FIGS. 11, 12, a honeycomb structure 159, which extends peripherally between each jacket, such as 135a, and the surrounding exoskeleton, such as 137a, plays this role and thus defines at least part of said means centering 157 above.

The honeycomb structure 159 may be annular. It can occupy a space between the bottom 135c of the shirts and that 137b of the exoskeleton considered (Figure12).

Including for the heat transfers sought, FIG. 13 shows that the jacket considered and the honeycomb structure, such as 159, are in contact by discrete zones, such as 159a, 159b,

Rather than in separate rooms, it would be possible to realize the liner and the honeycomb structure in one piece (Figure 13), so that they meet by these discrete zones located at the end radially inner walls 161 separating two cavities 163 of the cells.

Alternatively, it will be possible to make each jacket, such as 135a, said structure 159 which surrounds it and the exoskeleton, such as 137a, which surrounds this structure, in three distinct elements, dissociable between them, the jacket and the structure being engaged in the exoskeleton, concentrically, thus following a radial B to the axis A.

FIGS. 14 to 21, but this may apply to the preceding cases, the exoskeleton (s), such as 137a, individually comprises a radially outer end 137c (FIGS. 17, 18) towards which the constituted liner 135a is radially resting against a transverse surface 165 of the exoskeleton.

The radially outer end 137c can be opened.

An attached plug 167 (which may be removable) will then plug this radially outer end 137c.

The outer structure, in particular the exoskeleton (s), will be favorably mild steel, steels or alloys more or less refractory. Y will be slid axially an insert (the aforementioned folder) of metallic material as above and / or ceramic.

It will be understood that this allows:

- That the insert ensures the desired geometry for the casting and allows to control the solidification, by controlling the thermal stresses,

- And that the outer structure ensures the positioning of the mold on the centrifugal casting assembly and the mechanical strength of the assembly.

To persevere in the thermal control, preferably in combination with that of the forces, it is advised that, transversely to the radial direction in which they extend (axis B of the jacket considered), the shirts each have at least one thickness which varies along said radial direction (length L) and which is, at least overall, weaker towards at least one of the radially inner and outer ends, 134a, 134b, than in the intermediate portion, as shown in FIGS. 17, 18, 20; see also thicknesses e1, e2 and e3 figure 20. In other words, one can then find, along an axis B, a shape 133 firstly narrowing section from the end 133a, to a zone intermediate, then possibly (Figures 18,20) widening towards the opposite end 133b.

If necessary in connection with this aspect, FIGS. 17, 18, 20 show the advantage of having a mold where, individually, the radially open inner end 133a of the central duct 133 for casting the alloy of all or part of shirts 135 would have a shape 169 thus narrowing in section towards the center of the jacket, along the radial direction, B, according to which the corresponding jacket extends. It should be noted that the form 169 can thus be single or double funnel (head to tail). A truncated cone might be suitable.

As for the radially outer end portion of this conduit, near the end 134b (Figures 18,20), it can be supported, to present an enlarged end portion 133b.

Figure 20, we see that longitudinal reinforcements 171 may be provided to ensure the rigidity, centering and / or guiding the liner 135 concerned in the peripheral structure 137. The reinforcements are radially projecting relative to the remainder of the liner concerned.

A positioning of the reinforcements 171 towards the radial ends 134a, 134b will make it possible to disengage the intermediate zones along the length of the mold, such as at least one favorable space 1 55 for the control of thermal stresses and inertia, the objective being always achieve a low thermal inertia to allow homogeneous cooling of the cast metal form.

21, the reinforcements 171 are radial to the axis of the schematized sleeve and define therebetween several free spaces, or secondary cavities, such as 155a, 155b. For vacuum use of the mold, this (s) free space (s) and secondary cavities 155a, 155b established (es) between the peripheral structure 137 and the outer face of the shirt 135 considered, including if These are the outer surfaces of machined (half) shells, it is recommended that the space be "aired" outside of space 155.

For this, it is proposed that this space 155 is in fluid communication with the external environment of the mold via at least one orifice 175. In a particular embodiment, each bar 110 may have a length or axial dimension between 10 and 50cm, a section (such as an outer diameter) of between 5 and 20cm, an inner section (such as an inner diameter) of between 4 and 10cm and a radial thickness of between 1 and 10cm, on average at the location of a given section.

Claims

1. Set comprising:

characterized in that

the metal alloy is TiAl,

the mold is rotatable for centrifugal casting and comprises receiving housings (135) made of steel, metal alloy and / or ceramic suitable for centrifugally casting said molten TiAl alloy metal, and

- At the location of several cutting planes (P1, P2, P3 ...) each passing through the mold and the cast metal alloy, the mold has a surface thermal capacity (C1, Ci) lower than that (C1 ' , Ci ') of the cast metal alloy.

An assembly according to claim 1, comprising:

a plurality of said receiving housings (135) which extend radially (B) about the axis (A), and

at least one hollow exoskeleton (137) in which are housed shirts (135) which together define said housings, or the exoskeletons

(137) being open.

3. The assembly of claim 1 comprising:

- At least one hollow exoskeleton (137) which are housed shirts (135) which together define said housing, a void space (155) existing peripherally between each folder and the surrounding exoskeleton (137).

An assembly according to claim 1, comprising:

a plurality of said receiving housings (135) which extend radially (B) about the axis (A), and - At least one hollow exoskeleton (137) where housings (135) are located which all define said housings together, a honeycomb structure (163) extending peripherally between each liner and the surrounding exoskeleton.

5. Centrifuged casting mold, specific for the assembly according to claim 1, the mold being rotatable about an axis (A) and comprising:

a plurality of housings (135) for receiving a molten TiAl alloy extending radially (B) about the axis (A), and

- shirts (135) defining together said housings and which are housed in at least one hollow exoskeleton (137),

and the one or more exoskeletons is / are made of mild steel, steel or metal alloys and the shirts (135) are of mild steel, steel or metal and / or ceramic alloys.

6. Mold according to claim 5, characterized in that it comprises a central block (131) having ducts (132) through which the alloy is cast and which communicate with the inside of the shirts, and at least one attachment, preferably removable, (141a, 142a) is established:

- between each shirt and the surrounding exoskeleton, and / or

- between each shirt and / or the surrounding exoskeleton and the central block.

7. Mold according to one of claims 5 or 6, characterized in that the or the exoskeleton (137) is / are open.

8. Mold according to one of claims 5 to 7, characterized in that a void space exists peripherally between each folder and the exoskeleton (137) surrounding it.

9. Mold according to one of claims 5 to 8, characterized in that a honeycomb structure (163) extends peripherally between each jacket and the surrounding exoskeleton.

10. Mold according to one of claims 5 to 9, characterized in that, the shirts (135) being filled by the molten metal alloy, said mold has a surface thermal capacity (Ci, C1) lower than that (Ci ' , C1 ') of the metal alloy contained, and this at the location of several cutting planes (P1, P2, P3 ..) passing respectively through at least one of said shirts (135) and surrounding exoskeleton (137) and the metal alloy contained therein.

11. Use of a metal housing (135), steel alloy, metal alloy and / or ceramic mold for receiving a metal TiAl alloy according to one of claims 5 to 10, wherein in the mold, said molten TiAl metal alloy is brought by centrifugal casting, this mold and the cast metal alloy being such that the mold has, at the location of several cutting planes (P1, P2, P3 ..) each passing through the mold and the cast metal alloy, a surface thermal capacity (C1, Ci) lower than that (C1 ', Ci') of the cast metal alloy.