EP3439814B1 - Coulée de titane de cellule unitaire - Google Patents

Coulée de titane de cellule unitaire Download PDF

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Publication number
EP3439814B1
EP3439814B1 EP17779664.6A EP17779664A EP3439814B1 EP 3439814 B1 EP3439814 B1 EP 3439814B1 EP 17779664 A EP17779664 A EP 17779664A EP 3439814 B1 EP3439814 B1 EP 3439814B1
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EP
European Patent Office
Prior art keywords
crucible
mold
chamber
internal chamber
evacuated
Prior art date
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Active
Application number
EP17779664.6A
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German (de)
English (en)
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EP3439814A1 (fr
EP3439814A4 (fr
Inventor
Norm SMITH
Lowell WICKETT
Jan PARAISO
Mark Leposky
Jeff Cross
John Sheehan
Bill Richardson
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.)
Topgolf Callaway Brands Corp
Original Assignee
Callaway Golf Co
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 Callaway Golf Co filed Critical Callaway Golf Co
Priority claimed from PCT/US2017/025955 external-priority patent/WO2017176763A1/fr
Publication of EP3439814A1 publication Critical patent/EP3439814A1/fr
Publication of EP3439814A4 publication Critical patent/EP3439814A4/fr
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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D18/00—Pressure casting; Vacuum casting
    • B22D18/06—Vacuum casting, i.e. making use of vacuum to fill the mould
    • A—HUMAN NECESSITIES
    • A63—SPORTS; GAMES; AMUSEMENTS
    • A63B—APPARATUS FOR PHYSICAL TRAINING, GYMNASTICS, SWIMMING, CLIMBING, OR FENCING; BALL GAMES; TRAINING EQUIPMENT
    • A63B53/00—Golf clubs
    • A63B53/04—Heads
    • 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
    • B22D18/00—Pressure casting; Vacuum casting
    • B22D18/04—Low pressure casting, i.e. making use of pressures up to a few bars to fill the mould
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D18/00—Pressure casting; Vacuum casting
    • B22D18/08—Controlling, supervising, e.g. for safety reasons
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D21/00—Casting non-ferrous metals or metallic compounds so far as their metallurgical properties are of importance for the casting procedure; Selection of compositions therefor
    • B22D21/002—Castings of light metals
    • B22D21/005—Castings of light metals with high melting point, e.g. Be 1280 degrees C, Ti 1725 degrees C

Definitions

  • the present invention relates to precision titanium casting. More specifically, the present invention relates to an apparatus and method for precision titanium casting utilizing induction heating.
  • Vacuum electric arc smelting is another method in which a titanium ingot is melted by substantial heat generated by mutual discharging in a high current state by respectively using a titanium ingot crucible and a water-cooled copper crucible as a positive electrode and a negative electrode, thereby forming a molten liquid metal in the crucible and completing the casting of the titanium.
  • Another method is vacuum induction smelting in which an induction coil is wrapped outside a split-type water-cooled copper crucible.
  • the electromagnetic force generated by the induction coil passes through a nonmetal isolation portion between splits of the copper crucible and then acts on a titanium ingot placed inside the crucible. Then the molten metal forms a molten metal liquid inside the crucible and the casting of the titanium is completed.
  • Vacuum induction smelting and vacuum electric arc smelting require the use of a water-cooled copper crucible which results in the loss of substantial heat.
  • the actual power consumed is very little (only 20% to 30% of the power actually acts on the titanium).
  • the preparation of the molding shell is very complex and time consuming, which adds to the costs.
  • the operation time of a single furnace is usually 60 to 80 minutes, and the loading and discharge process requires the coordination of many people.
  • the process from the preparation of the wax pattern to the clearing of the molding shell can take ten days.
  • Titanium is an extremely reactive metal. During melting via traditional casting processes, a water cooling environment is required. The molten titanium liquid will come into direct contact with water if the crucible cracks, resulting in a fierce reaction, or even explosion, which poses a great threat to production safety.
  • CN104646647 discloses a titanium-based alloy induction melting bottom leakage type vacuum suction casting device and a control method for carrying out vacuum induction melting on titanium-based alloy by adopting a ceramic crucible.
  • the pattern mold itself is currently affixed to the underside of the top plate of the inner chamber utilizing a forked wedge.
  • the top plate (with mold attached) is then inverted and placed onto the inner chamber body.
  • a cradle should be utilized to support the mold.
  • the cradle would be created within the inner chamber and be designed specifically to hold and orient the pattern mold.
  • the pattern mold itself would be modified to create a funnel at the top of the main gate to allow material to flow into and fill the mold. The use of this feature will allow for faster/more repeatable cycle times which will minimize part to part variation.
  • One aspect of the present invention is a method for unit cell casting of titanium or titanium-alloys.
  • the method includes evacuating an external chamber to create an evacuated external chamber wherein a ceramic crucible containing a titanium alloy ingot is positioned therein.
  • the method also includes injecting a pressurized gas into the evacuated external chamber to create a pressurized external chamber.
  • the method also includes melting the titanium alloy ingot within the ceramic crucible utilizing induction heating generated by an induction coil positioned around the ceramic crucible.
  • the method also includes evacuating the internal chamber to create an evacuated internal chamber, wherein a mold is positioned within the pattern mold cradle within the internal chamber.
  • the method also includes transferring the completely melted titanium alloy material into the mold from the crucible using a pressure differential created between the external chamber and the internal chamber.
  • a frequency generated in the induction coil ranges from 1 kilo-Hertz to 50 kilo-Hertz, and a power ranges from 15 kilo-Watts to 50 kilo-Watts.
  • An atmospheric pressure of the evacuated internal chamber ranges from 9.87 ⁇ 10 -7 atmosphere to 9.87 ⁇ 10 -13 atmosphere.
  • the method further comprises heating the mold using an infrared heating unit positioned within the internal chamber to create a heated mold.
  • the method further comprises cooling the titanium alloy within the mold.
  • Another aspect of the present invention is a system for unit cell casting of titanium or titanium-alloys, the system comprises an external chamber, a ceramic crucible positioned within the external chamber, an induction coil positioned around a bottom section of the ceramic crucible, an internal chamber positioned within the external chamber, a pattern mold cradle within the internal chamber, and a mold positioned within the pattern mold cradle within the internal chamber.
  • the external chamber is evacuated to create an evacuated external chamber wherein the ceramic crucible contains a titanium alloy ingot positioned therein.
  • a pressurized gas is injected into the evacuated external chamber to create a pressurized external chamber.
  • the titanium alloy ingot is melted within the ceramic crucible utilizing induction heating generated by the induction coil positioned around the ceramic crucible.
  • the internal chamber is evacuated to create an evacuated internal chamber.
  • the titanium alloy material is completely transferred into the mold from the crucible using a pressure differential created between the external chamber and the internal chamber.
  • the pressurized gas is preferably argon.
  • the mold is preferably covered in a kaolin wool insulating material.
  • the mold is preferably for a thin-walled golf club head.
  • the mold is alternatively for an article having a wall thickness less than 0.250 inch (6.35 mm).
  • the induction melting time preferably ranges from 30 seconds to 90 seconds.
  • the ceramic crucible is preferably composed of two yttria-based primary crucible layers, wherein a first primary crucible layer has a thickness ranging from 0.010inch to 0.060inch (0.254 mm to 1.524 mm), and a second primary crucible layer has a thickness ranging from 0.001inch to 0.020inch (0.0254 mm to 0.508 mm).
  • the ceramic crucible further comprises a silica based backup layer.
  • the induction coil is positioned around a bottom section of the ceramic crucible.
  • a unit cell titanium casting system 5 comprises an external container 44, an internal container 39, a vacuum mechanism 60, a crucible 10, an induction coil 15, a coil electrical generation mechanism 25, and a mold 30.
  • the external container 44 defines an external chamber 45.
  • the internal container 39 defines an internal chamber 40.
  • the vacuum mechanism 60 includes a vacuum line 71, a vacuum connector 70 and pressure gauges 75a and 75b. The vacuum mechanism 60 is utilized to evacuate and pressurize the external chamber 45 and the internal chamber 40 in order to create a pressure differential between the internal chamber 40 and the external chamber 45.
  • the crucible 10 is preferably composed of a ceramic material.
  • the crucible 10 is composed of a first layer 11a, a second layer 11b and a silica based third layer 11c, as shown in FIG. 7 .
  • a metal ingot 20 is placed within the interior of the crucible 10.
  • the metal ingot 20 is preferably a titanium alloy material.
  • the volume of the crucible 10 preferably corresponds to the amount of metal necessary for forming the article.
  • the interior of the crucible 10 preferably has a diameter ranging from 15 centimeters ("cm") to 90cm, more preferably from 35cm to 60cm.
  • a height of the crucible 10 preferably ranges 30cm to 200cm, and more preferably from 60cm to 100cm.
  • connection nozzle 27 is connected between a bottom opening (not shown) of the crucible 10 and an opening to the mold 30.
  • the connection nozzle 27 allows the melted metal material from the ingot 20 to flow into the mold 30 for casting of the article.
  • the size of connection nozzle 27 is determined based on the size and shape of the cavity of the mold 30, and is preferably from 5cm to 100cm, and more preferably from 15cm to 50cm.
  • the induction coil 15 is wrapped around the crucible 10.
  • the induction coil 15 is energized to generate an electromagnetic force to melt the metal ingot 20 (e.g., titanium alloy ingot) within the crucible 10.
  • the coil electrical generation mechanism 25 provides the electricity to the induction coil 15.
  • the induction coil 15 is wrapped around a bottom section 10b of the crucible 10. This melts the bottom of the ingot 20 first.
  • the induction coil 15 is wrapped around an upper section 10a of the crucible 10. This melts the top of the ingot 20 first.
  • the induction coil 15 may be centered on the upper third of the ingot 20. This positioning allows the induction coil 15 to first act on the upper portion of the ingot 20 (melting the material from the top down), causing molten material to cascade around the still-solid ingot 20 and forming a seal before the electromagnetic forces of the induction coil 15 affect the remaining material.
  • the induction coil 15 in order to fully utilize the electromagnetic forces of the induction coil 15, to include the electromagnetic stirring of the melt, the induction coil 15 is positioned towards the bottom 10b of the ceramic crucible 10. This positioning allows for a uniform melt as molten material cascades onto itself and also increased homogeneity of the pour as the electromagnetic forces can better act on the molten material prior to it being evacuated from the crucible 10.
  • Melting of the ingot 20 of titanium alloy is carried out in a vacuum condition for induction melting.
  • the induction coil 15 is connected to the coil electrical generation mechanism 25.
  • the ceramic crucible 10 is utilized for vacuum induction melting of the titanium alloy.
  • the ceramic material does not interfere with the fielding effect of the electromagnetic force, and the electro-magnetic induction energy generated by the induction coil 15 is fully focused on melting the ingot of titanium alloy.
  • an insulating material 31 is wrapped around the mold 30.
  • pattern molds are preheated prior to use in order to improve the flow of material into the mold itself and to better allow the mold 30 to fill completely. Due to the nature of titanium materials, and the melting process itself, the more that heat loss is minimized, the greater time the material has to flow and fill the mold 30 prior to solidification. To this end, pattern mold heat is retained through the use of an insulating material 31 (e.g.: Kaolin wool) thereby extending the useful period of the mold 30 prior to the pour and allowing for better fill, including filling of more difficult molds (e.g., thin walled castings).
  • an insulating material 31 e.g.: Kaolin wool
  • the mold 30 is preheated in an oven 80.
  • pattern molds 30 are preheated prior to use in order to improve the flow of material into the mold 30 itself and to better allow the mold 30 to fill completely. Due to the nature of titanium materials, and the melting process itself, there is a likely correlation between the temperature of the mold 30 and the ability to fill complex and/or thin walled pattern molds 30. Temperatures testing include 1050°C, 1060°C, 1100°C, 1150°C, 1200°C, 1250°C and 1260°C.
  • the pre-heated mold is removed from the 80 and attached to a lid 35 of the internal container 39.
  • infrared heaters 50a and 50b are used to maintain the heat of the mold 30 within the internal chamber 40. Due to the nature of titanium materials, and the melting process itself, the more that heat loss is minimized, the greater time the material can flow and fill the mold 30 prior to solidification. To this end, pattern mold heat is retained through the use of infrared heaters 50a and 50b placed within the internal walls of the internal chamber 40 of the internal container 39 in order to minimize pattern mold cool down and improve the ability to cast complex and/or thin-walled parts.
  • FIGS. 4, 4A and 4B illustrate the casting process using a pressure differential between the external chamber 45 and the internal chamber 40 to assist in the flow of melted titanium alloy materials into a mold 30.
  • FIG. 5 illustrates a programmable logic computer ("PLC”) and operator computer 91 utilized with the unit cell casting system 5.
  • PLC programmable logic computer
  • FIG. 6 is a block diagram of a unit cell casting method 600.
  • an ingot 20 is prepared for casting.
  • the single ingot 20 is utilized to manufacture a single article such as a golf club head 29.
  • the present invention manufactures only a single article in each process.
  • the mold 30 is preheated in an oven.
  • the external chamber 45 is evacuated.
  • the external chamber 45 is pressurized with an argon gas.
  • the internal chamber 40 is evacuated.
  • the induction coil 15 is energized and at step 607 the ingot 20 is melted within the crucible 10.
  • the melted material flows into mold 30.
  • the de-molding process occurs.
  • the article (golf club head) 29 is finished.
  • a frequency generated in the induction coil ranges from 1 kilo-Hertz to 50 kilo-Hertz, and a power ranges from 15 kilo-Watts to 50 kilo-Watts.
  • An atmospheric pressure of the evacuated internal chamber ranges from 9.87 ⁇ 10 -7 atmosphere to 9.87 ⁇ 10 -13 atmosphere.
  • the first layer 11a and the second layer 11b are preferably composed of yttrium oxide and other materials.
  • Yttrium oxide is highly inert to titanium in a high-temperature environment resulting in no chemical reaction between the two materials.
  • Yttrium oxide also isolates the ceramic material from the titanium during the melting process to prevent reaction between them to ensure the smooth melting of the titanium-alloy.
  • the third layer 11c of the crucible 10 is preferably composed of silicon dioxide and other materials. The silicon dioxide resists the metallic expansion and thermal stress during the melting process to ensure strength of the crucible.
  • a preferred thickness of the first layer 11a is from 0.5mm to 1.5mm and the preferred thickness range of the crucible 10 is from 5mm to 15mm.
  • a method 800 for unit cell casting of titanium or titanium-alloys is shown in FIG. 8 .
  • an external chamber is evacuated to create an evacuated external chamber wherein a ceramic crucible containing a titanium alloy ingot is positioned therein.
  • a pressurized gas is injected into the evacuated external chamber to create a pressurized external chamber.
  • the titanium alloy ingot is melted within the ceramic crucible utilizing induction heating generated by an induction coil positioned around the ceramic crucible.
  • the internal chamber is evacuated to create an evacuated internal chamber, wherein a mold is positioned within the internal chamber.
  • the completely melted titanium alloy material is transferred into the mold from the crucible using a pressure differential created between the external chamber and the internal chamber.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Health & Medical Sciences (AREA)
  • General Health & Medical Sciences (AREA)
  • Physical Education & Sports Medicine (AREA)
  • Crucibles And Fluidized-Bed Furnaces (AREA)
  • Manufacture And Refinement Of Metals (AREA)
  • Dental Prosthetics (AREA)

Claims (10)

  1. Procédé (800) de coulée de cellule unitaire de titane ou d'alliages de titane, le procédé comprenant :
    l'évacuation d'une chambre externe (45) pour créer une chambre externe évacuée (45), un creuset (10) contenant un lingot d'alliage de titane (20) y étant positionné ;
    l'injection (802) d'un gaz sous pression dans la chambre externe évacuée (45) pour créer une chambre externe sous pression (45) ;
    la fusion (803) du lingot d'alliage de titane (20) dans le creuset (10) en utilisant le chauffage par induction généré par une bobine d'induction (15) positionnée autour du creuset (10) ;
    l'évacuation (804) d'une chambre interne (40) positionnée à l'intérieur de la chambre externe (45) pour créer une chambre interne évacuée (45), un moule (30) étant positionné à l'intérieur de la chambre interne (45) ; et
    le transfert (805) du matériau en alliage de titane complètement fondu dans le moule (30) depuis le creuset (10) en utilisant un différentiel de pression créé entre la chambre externe (45) et la chambre interne (40) ;
    une fréquence générée dans la bobine d'induction (15) étant dans la plage de 1 kilo-Hertz à 50 kilo-Hertz, et une puissance étant dans la plage de 15 kilo-Watts à 50 kilo-Watts ;
    caractérisé en ce qu'une pression atmosphérique de la chambre interne évacuée (45) est dans la plage de 9,87×10-7 atmosphère à 9,87×10-13 atmosphère,
    la bobine d'induction (15) est positionnée autour d'une section inférieure du creuset (10), et
    le procédé comprend en outre le chauffage du moule (30) à l'aide d'une unité de chauffage infrarouge (50a, 50b) positionnée dans la chambre interne (45) pour créer un moule chauffé (30).
  2. Procédé (800) selon la revendication 1, le gaz sous pression étant de l'argon.
  3. Procédé (800) selon la revendication 1, le temps de fusion par induction étant dans la plage de 30 à 90 secondes.
  4. Procédé (800) selon la revendication 3, le creuset (10) comprenant une couche de sauvegarde à base de silice.
  5. Procédé (800) selon la revendication 1, comprenant en outre le refroidissement de l'alliage de titane dans le moule (30).
  6. Système (5) pour la coulée de cellule unitaire de titane ou d'alliages de titane, comprenant :
    une chambre externe (45) ;
    un creuset en céramique (10) positionné à l'intérieur de la chambre externe (45) ;
    une bobine d'induction (15) positionnée autour du creuset en céramique (10) ;
    une chambre interne (40) positionnée à l'intérieur de la chambre externe (45) ;
    un cadre de moule à motif dans la chambre interne (40) ; et
    un moule (30) positionné dans le cadre de moule à motif à l'intérieur de la chambre interne (40) ;
    la chambre externe (45) étant configurée pour être évacuée afin de créer une chambre externe évacuée (45), le creuset en céramique (10) contenant un lingot d'alliage de titane (20) positionné à l'intérieur de celui-ci ;
    un gaz sous pression étant injectable dans la chambre externe évacuée (45) pour créer une chambre externe sous pression (45) ;
    le lingot d'alliage de titane (20) pouvant être fondu à l'intérieur du creuset en céramique (10) en utilisant le chauffage par induction généré par la bobine d'induction (15) positionnée autour du creuset en céramique (10) ;
    la chambre interne (40) étant configurée pour être évacuée afin de créer une chambre interne évacuée (45) ;
    le matériau en alliage de titane étant complètement transférable dans le moule (30) depuis le creuset (10) en utilisant un différentiel de pression créé entre la chambre externe (45) et la chambre interne (40),
    caractérisé en ce qu'une pression atmosphérique de la chambre interne évacuée est dans la plage de 9,87×10-7 atmosphère à 9,87×10-13 atmosphère,
    la bobine d'induction (15) est positionnée autour d'une section inférieure du creuset en céramique (10), et
    le système (5) comprend en outre une unité de chauffage à infrarouge (50a, 50b) dans la chambre interne (40), le moule (30) étant chauffé en utilisant une unité de chauffage à infrarouge (50a, 50b) positionnée à l'intérieur de la chambre interne (40) pour créer un moule chauffé (30).
  7. Procédé (800) selon la revendication 1 ou système (5) selon la revendication 6, le moule (30) étant destiné à une tête de club de golf à paroi mince.
  8. Procédé (800) selon la revendication 1 ou système (5) selon la revendication 6, le moule (30) étant destiné à un article ayant une épaisseur de paroi inférieure à 0,250 pouce (6,35 mm).
  9. Procédé selon la revendication 1 ou système selon la revendication 6, le creuset en céramique étant composé de deux couches de creuset primaire à base d'oxyde d'yttrium, une première couche de creuset primaire ayant une épaisseur dans la plage de 0,010 pouce à 0,060 pouce (0,254 mm à 1,524 mm), et une seconde couche de creuset primaire ayant une épaisseur dans la plage de 0,001 pouce à 0,020 pouce (0,0254 mm à 0,508 mm).
  10. Procédé (800) selon la revendication 1 ou système (5) selon la revendication 6, le moule étant recouvert d'un matériau isolant en laine de kaolin (31).
EP17779664.6A 2016-04-06 2017-04-04 Coulée de titane de cellule unitaire Active EP3439814B1 (fr)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
US201662319215P 2016-04-06 2016-04-06
US201662318854P 2016-04-06 2016-04-06
PCT/US2017/025955 WO2017176763A1 (fr) 2016-04-06 2017-04-04 Coulée de titane de cellule unitaire

Publications (3)

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EP3439814A1 EP3439814A1 (fr) 2019-02-13
EP3439814A4 EP3439814A4 (fr) 2019-09-18
EP3439814B1 true EP3439814B1 (fr) 2020-12-09

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CN (1) CN108883463A (fr)
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CN116274895B (zh) * 2023-03-23 2023-11-07 陕西天成航空材料有限公司 一种成分均匀钛合金铸锭的制备方法

Family Cites Families (7)

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Publication number Priority date Publication date Assignee Title
US4478270A (en) * 1981-04-01 1984-10-23 Interlake, Inc. Apparatus for casting low-density alloys
US5193607A (en) * 1990-05-15 1993-03-16 Daido Tokushuko K.K. Method for precision casting of titanium or titanium alloy
RU2036049C1 (ru) * 1991-03-19 1995-05-27 Всероссийский научно-исследовательский институт авиационных материалов Установка для изготовления отливок направленной кристаллизацией
JP2842417B2 (ja) * 1996-11-28 1999-01-06 三菱マテリアル株式会社 ゴルフクラブヘッド
RU2300443C1 (ru) * 2005-09-15 2007-06-10 Федеральное государственное унитарное предприятие "Московское машиностроительное производственное предприятие "Салют" Устройство для литья в вакууме
CN204584231U (zh) * 2015-01-16 2015-08-26 马旭东 钛基合金感应熔炼底漏式真空吸铸设备
CN104646647B (zh) * 2015-01-16 2017-03-15 北京嘉毅万思科技发展有限公司 钛基合金感应熔炼底漏式真空吸铸设备及控制方法

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EP3439814A1 (fr) 2019-02-13
EP3439814A4 (fr) 2019-09-18
CN108883463A (zh) 2018-11-23
TW201738389A (zh) 2017-11-01

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