EP3248710A1 - Procédé de fabrication d'un moule de coulée pour des pièces creuses - Google Patents

Procédé de fabrication d'un moule de coulée pour des pièces creuses Download PDF

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Publication number
EP3248710A1
EP3248710A1 EP16170817.7A EP16170817A EP3248710A1 EP 3248710 A1 EP3248710 A1 EP 3248710A1 EP 16170817 A EP16170817 A EP 16170817A EP 3248710 A1 EP3248710 A1 EP 3248710A1
Authority
EP
European Patent Office
Prior art keywords
model
mold
container
casting
ceramic slurry
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Withdrawn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
EP16170817.7A
Other languages
German (de)
English (en)
Inventor
Heinz-Jürgen GROSS
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.)
Siemens AG
Original Assignee
Siemens AG
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 Siemens AG filed Critical Siemens AG
Priority to EP16170817.7A priority Critical patent/EP3248710A1/fr
Publication of EP3248710A1 publication Critical patent/EP3248710A1/fr
Withdrawn legal-status Critical Current

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Classifications

    • 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
    • B22C7/023—Patterns made from expanded plastic materials
    • 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
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/22—Moulds for peculiarly-shaped castings
    • B22C9/24—Moulds for peculiarly-shaped castings for hollow articles

Definitions

  • the invention relates to a method for producing a casting mold for a workpiece, which defines at least one cavity in its interior.
  • the invention relates to a method for casting a turbine blade using a mold, which is produced in a method according to the invention.
  • Methods of making molds for workpieces that define at least one cavity therein are known in the art in various forms and are used, for example, to make molds for investment casting of cooled turbine blades.
  • Current turbine blades for turbomachines each include at least one blade platform and an airfoil projecting from the blade platform in a longitudinal direction. They often define in their interior at least one cavity which is flowed through during the operation of the turbomachine by a cooling fluid.
  • casting cores in a first method step, the outer contours of which essentially correspond to the inner contours of the desired cavities.
  • These cores are often produced by a casting process itself.
  • a ceramic slurry is poured into a corresponding casting core molds and hardened in this to form a green body. Then, the green body is released from the casting core mold and cured by sintering or firing.
  • spacer elements are then fastened to the casting cores, which extend outward between the casting cores and starting from the casting cores.
  • the casting cores which keep the cavities of the later turbine blade free are then surrounded with a model material, for example a wax, such that the outer contour of the model material is arranged outside the outer contour of the turbine blade to be produced.
  • a model material for example a wax
  • the model material is processed such that its outer contour corresponds substantially to the outer contour of the turbine blade to be cast.
  • the model prepared in this way is finally sanded in several layers, with a mixture of a binder such as an adhesive and sand from the outside is applied to the model. Each layer of sand must solidify before another can be applied. The sanding of the model is repeated until the resulting sand layer on the model has reached the desired thickness.
  • a binder such as an adhesive and sand from the outside
  • the outer wall of the mold is cured by sintering or firing, wherein preferably also the model material is removed by melting or sublimation from the mold.
  • the invention is based on the idea of producing a complete model of the workpiece to be cast in one process step.
  • the model is formed by means of an additive manufacturing process of a model material such that its outer and inner contours substantially coincide with the outer and inner contours of the workpiece to be cast.
  • the previously required separate production of the cores can be completely eliminated.
  • Another advantage is that with the proposed method, such workpieces can be produced in a simple manner, which are not or not economically feasible due to complex contoured cavities by conventional methods. For example, casting molds for workpieces with helical cavities or cavities with undercuts can be produced with the method according to the invention, which are not or at least not economically producible with known methods.
  • a thermal printing process is carried out in step a).
  • Such methods are characterized by easy implementation and low costs.
  • a wax in particular a glass fiber reinforced plastic or a metal is used as a model material.
  • a glass fiber reinforced plastic or a metal is used as a model material.
  • the alternatives mentioned are not meant to be exhaustive. Virtually any material that can be processed in an additive manufacturing process that can be removed from the mold after completion of the mold is suitable for the proposed method of making a mold.
  • the model may be inserted in a container such that its inner surface is spaced from the outer surface of the model and the gap between the inner surface of the container and the outer surface of the model and the at least one cavity of the model is completely filled with the mold material.
  • the inner contour of the container defines the outer contour of the mold to be produced. It can for example be chosen so that the outer wall of the mold has a substantially constant thickness.
  • the container is advantageously produced in step a) simultaneously with the model additive. This leads to a particularly elegant method, in which the outer shapes of the mold to be produced can be arbitrarily specified.
  • a ceramic slurry is used as the casting material, which solidifies in the container to form a green body, wherein the green body is cured after step b) by supplying thermal energy, in particular by sintering or firing.
  • the ceramic slurry solidifies by oxidation of the ceramic slurry, volatilization of a solvent of the ceramic slurry or a chemical reaction of at least two components of the ceramic slurry. With such a ceramic slurry no energy supply is required to form the green body.
  • step b) and step c the container can be separated from the casting material, in particular, the container is destroyed. As a result, the mold is exposed on its outside.
  • thermal energy is supplied to the model material in step c) to cause melting or sublimation of the model material, or a solvent is added to dissolve the model material.
  • the interior of the mold is exposed to fill the mold with a casting material for the production of the workpiece.
  • the model material can also be filled of the casting material are removed from the casting mold by the casting material itself.
  • the present invention provides a method of casting a turbine blade using a mold made in a method according to the invention, wherein the model made in step a) substantially conforms to the outer and inner contours of the turbine blade to be cast in terms of its outer and inner contours matches.
  • the model made in step a) substantially conforms to the outer and inner contours of the turbine blade to be cast in terms of its outer and inner contours matches.
  • FIGS. 1 and 2 show a common turbine blade 1 for turbomachinery.
  • the turbine blade 1 includes a blade platform 2 and an airfoil 3 projecting from the blade platform 2 in a longitudinal direction L. Furthermore, the turbine blade 1 comprises a blade root 4, which protrudes from the blade platform 2 opposite to the blade 3.
  • cavities 5 are provided, which are flowed through during the operation of the turbine blade 1 by a cooling fluid.
  • the cavities 5 are separated from one another by webs 6, which extend from the blade platform 2 and / or the blade tip 7 in the longitudinal direction L of the turbine blade 1.
  • FIGS. 3 to 5 show various stages of a method of manufacturing a mold 8 according to an embodiment of the present invention.
  • the mold 8 thus produced can be used for investment casting in the FIGS. 1 and 2 illustrated turbine blade 1 can be used.
  • a complete model 9 is made of a model material 9a, the outer and inner contours of which substantially coincide with the outer and inner contours of the turbine blade 1 to be cast.
  • a thermal printing process is carried out, for example using a laser, but other additive manufacturing processes can also be used to fabricate the laser Model 9 will be applied.
  • a wax is used as model material 9a.
  • deviating materials such as glass fiber reinforced plastics or metals or metal alloys are also suitable if they can be processed in an additive manufacturing process.
  • FIG. 3 shows the model 9 and the container 10 after completion of the process step a).
  • the model 9 can also be used in a separately manufactured container.
  • the inner surface of the container must be arranged to form a gap 11 spaced from the outer surface of the model 9.
  • the intermediate space 11 and the cavities 5 are filled with a ceramic slip.
  • the ceramic slurry solidifies in the container 10 to form a green body.
  • the solidification can take place by oxidation of the ceramic slurry, volatilization of a solvent of the ceramic slurry or a chemical reaction of at least two components of the ceramic slurry.
  • casting mold materials deviating from a ceramic slurry may also be used which solidify in the container 10.
  • This stage of the procedure is in FIG. 4 as a result of step b).
  • step c) is the in FIG. 5 illustrated mold 8 completed.
  • the mold 8 is used to cast a turbine blade in a conventional manner.
  • One advantage of the proposed method is that it is possible to dispense with the very complex preprocessing of casting cores to keep the cavities 5 free. Instead, the cores are made simultaneously with the outer wall of the mold 8. Furthermore, it is advantageous that, as a result, workpieces can also be produced whose cavities can not be produced due to their complex contours in known casting methods. These include, for example, helical cavities or cavities with undercuts, which opens the way to more effective cooling systems in the fall of turbine blades.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Turbine Rotor Nozzle Sealing (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
EP16170817.7A 2016-05-23 2016-05-23 Procédé de fabrication d'un moule de coulée pour des pièces creuses Withdrawn EP3248710A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
EP16170817.7A EP3248710A1 (fr) 2016-05-23 2016-05-23 Procédé de fabrication d'un moule de coulée pour des pièces creuses

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
EP16170817.7A EP3248710A1 (fr) 2016-05-23 2016-05-23 Procédé de fabrication d'un moule de coulée pour des pièces creuses

Publications (1)

Publication Number Publication Date
EP3248710A1 true EP3248710A1 (fr) 2017-11-29

Family

ID=56068773

Family Applications (1)

Application Number Title Priority Date Filing Date
EP16170817.7A Withdrawn EP3248710A1 (fr) 2016-05-23 2016-05-23 Procédé de fabrication d'un moule de coulée pour des pièces creuses

Country Status (1)

Country Link
EP (1) EP3248710A1 (fr)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN110052583A (zh) * 2019-03-15 2019-07-26 启东市聚旺铸造有限公司 一种空心导向叶片精密铸造工艺
CN115041631A (zh) * 2022-05-30 2022-09-13 西安交通大学 一种空心涡轮叶片的多材料一体化铸型的制备方法及铸型

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20060065383A1 (en) * 2004-09-24 2006-03-30 Honeywell International Inc. Rapid prototype casting
CA2643279A1 (fr) * 2008-11-07 2010-05-07 General Electric Company Procedes de fabrication de composants d'une turbine a gaz a l'aide d'une matrice centrale a coquille jetable
US20140209268A1 (en) * 2013-01-29 2014-07-31 General Electric Company Calcium hexaluminate-containing mold and facecoat compositions and methods for casting titanium and titanium aluminide alloys

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20060065383A1 (en) * 2004-09-24 2006-03-30 Honeywell International Inc. Rapid prototype casting
CA2643279A1 (fr) * 2008-11-07 2010-05-07 General Electric Company Procedes de fabrication de composants d'une turbine a gaz a l'aide d'une matrice centrale a coquille jetable
US20140209268A1 (en) * 2013-01-29 2014-07-31 General Electric Company Calcium hexaluminate-containing mold and facecoat compositions and methods for casting titanium and titanium aluminide alloys

Non-Patent Citations (5)

* Cited by examiner, † Cited by third party
Title
A. ROSOCHOWSKI, A. MATUSZAK: "Rapid tooling: the state of art", JOURNAL OF MATERIAL PROCESSING TECHNOLOGY, vol. 106, 2000, XP002763850 *
BRIAN ROOKS: "Rapid tooling for casting prototypes", ASSEMBLY AUTOMATION, EMERALD GROUP PUBLISHING LTD, GB, vol. 22, no. 1, 1 January 2002 (2002-01-01), pages 40 - 45, XP009190683, ISSN: 0144-5154, DOI: 10.1108/01445150210416664 *
GAIER D ET AL: "Applications of Rapid Prototyping Technologies at High Tech Castings, Inc", SAE TECHNICAL PAPER 941229,, 1 April 1994 (1994-04-01), pages 1 - 9, XP009190689, DOI: 10.4271/941229 *
K. WANCZYK, A. GIL, P. KOWALSKI: "The Use of Rapid Prototyping Methods to Perform Flexible Pattern Mold for Compressor Turbine Casting in the Gypsum Molds", ARCHIVES OF FOUNDRY ENGINEERING, vol. 15, no. 3, 2015, XP002763852 *
PAUL CALVERT: "Inkjet Printing for Materials and Devices", CHEM. MATER., vol. 13, 2001, XP002763851 *

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN110052583A (zh) * 2019-03-15 2019-07-26 启东市聚旺铸造有限公司 一种空心导向叶片精密铸造工艺
CN115041631A (zh) * 2022-05-30 2022-09-13 西安交通大学 一种空心涡轮叶片的多材料一体化铸型的制备方法及铸型
CN115041631B (zh) * 2022-05-30 2023-10-27 西安交通大学 一种空心涡轮叶片的多材料一体化铸型的制备方法及铸型

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