EP3463714B1 - Mould for manufacturing a single-crystal blade by casting, installation and method of manufacture implementing same - Google Patents

Mould for manufacturing a single-crystal blade by casting, installation and method of manufacture implementing same Download PDF

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Publication number
EP3463714B1
EP3463714B1 EP17733496.8A EP17733496A EP3463714B1 EP 3463714 B1 EP3463714 B1 EP 3463714B1 EP 17733496 A EP17733496 A EP 17733496A EP 3463714 B1 EP3463714 B1 EP 3463714B1
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EP
European Patent Office
Prior art keywords
blade
mold
cavity
duct
segment
Prior art date
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EP17733496.8A
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German (de)
French (fr)
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EP3463714A1 (en
Inventor
Ngadia Taha NIANE
Saïd BOUKERMA
Serge Dillenseger
Julien GELEBART
David Grange
Jean-Claude Marcel Auguste Hanny
Philippe METRON
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Safran Aircraft Engines SAS
Safran SA
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Safran Aircraft Engines SAS
Safran SA
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    • 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
    • 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
    • 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
    • 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 general field of processes for manufacturing parts by casting.
  • the invention relates more particularly to a mold for manufacturing a single crystal turbomachine blade by lost wax casting.
  • metal parts or metal alloy parts which have a controlled monocrystalline structure.
  • the blades In certain cases, and in particular in aeronautical turbomachines, it is necessary to have metal parts or metal alloy parts which have a controlled monocrystalline structure.
  • the blades In the distributors of turbines of aeronautical turbomachines, the blades must withstand significant thermomechanical stresses due to the high temperature and to the centrifugal forces to which they are subjected.
  • a controlled monocrystalline structure in the metal alloys forming these blades makes it possible to limit the effects of these stresses.
  • a wax model of the part to be manufactured is first produced, around which a ceramic shell is formed, forming a mold.
  • a molten metal is then poured into the mold, and the directed solidification of the metal makes it possible to obtain, after removal from the mold, the molded part.
  • This process is advantageous for manufacturing metal parts of complex shapes, and makes it possible to obtain parts having a monocrystalline structure by using, for example, a seed or a grain selector duct.
  • the blades generally consist of a foot, a platform fitted with spoilers, a blade, a heel fitted with spoilers, and wipers.
  • the parts of the mold cavity forming in particular the spoilers of the platform and the heel solidify with a some delay with respect to other parts of the cavity such as that forming the blade. This delay can lead to the appearance of undesirable porosities in the final part.
  • the blade can present in certain places and in particular on the leading edge or the trailing edge near the platform. or of the heel, parasitic recrystallized grains. This is not desirable when it is desired to obtain a single crystal blade.
  • the blades obtained can exhibit a significant variation in dimensions between the wax model and the final part, and can sometimes be deformed or twisted.
  • auxiliary grain duct ensures that the platform and the heel of the vane do not solidify last, which reduces the appearance of porosity-type defects in these portions of the vane. .
  • the auxiliary grain duct acts as a stay which holds the vane and stiffens it throughout the manufacturing process. By maintaining it in this way, the residual stresses which may remain in the vane are reduced, and the appearance of recrystallized grains after heat treatment is also reduced.
  • the inventors have observed that the blade obtained with a mold according to the invention has dimensions which are closer to those desired, compared to a blade manufactured in a mold without an auxiliary grain duct. The inventors have also observed that the blade obtained is less twisted when it is manufactured in a mold according to the invention.
  • the auxiliary grain duct can be positioned opposite the leading edge or the trailing edge of the vane.
  • the second portion of the auxiliary grain duct may include a weight at each of its ends.
  • the first portion may include a flyweight at one end.
  • the blade may be a blade for an aircraft turbomachine turbine.
  • the second portion of the auxiliary grain duct may have a necking, that is to say a local narrowing of its section, for example at the level of the middle of said second portion.
  • the auxiliary grain duct will be able to break more easily at the level of this necking during demolding.
  • the invention also relates to an installation for manufacturing a blade molded from a molten metal, comprising a mold such as that presented above, and means for obtaining monocrystalline grain connected to the mold.
  • the means for obtaining monocrystalline grain can comprise a monocrystalline seed or a grain selector duct.
  • the method may further comprise a step of heat treatment of the blade obtained.
  • This heat treatment makes it possible to relax the residual stresses inside the molded blade which may be due in particular to the molding and to the solidification of the metal, in order to obtain a stable microstructure and controlled mechanical properties in the final part.
  • the figure 1 shows an installation 1 for manufacturing by foundry a single crystal aeronautical turbomachine turbine blade according to the invention.
  • the installation 1 comprises a cup 2 through which a molten metal can be poured, the cup 2 is configured to fill with this metal a mold 3 comprising a cavity 4 having here the shape of a blade of an aircraft turbomachine turbine.
  • the mold 3 comprises, in accordance with the invention, an auxiliary grain duct 5.
  • the mold 4 surmounts and is connected to a grain selector duct 6 which makes it possible to obtain a monocrystalline blade after a directed solidification of the metal present in the mold. 3.
  • the installation shown in figure 1 is intended to manufacture a single blade, it is of course conceivable to have an installation for manufacturing a plurality of blades.
  • the figure 2 shows a sectional view of the cavity 4 of the mold 3 to which is connected the auxiliary grain duct 5. It will be noted that on the figures 1 and 2 , for greater readability, the ceramic material wall of the installation 1 and of the mold 3 has not been shown; in other words, these figures show only the internal parts of the installation 1 or of the mold 3 into which a molten metal can be introduced.
  • upstream and downstream are defined in relation to the direction flow of the gas flow around the blade when the blade is mounted in a turbomachine.
  • the cavity 4 has the shape of an aeronautical turbomachine turbine blade and comprises: a part 40 forming the root of the blade, a part 41 forming the platform of the blade, a part 42 forming the blade of the blade , and a part 43 forming the heel of the blade.
  • the part 40 forming the root is connected at its bottom to the grain selector duct 6.
  • the blade extends longitudinally between a root and a top.
  • the platform is positioned on the side of the lower end of the blade, between the root and the blade, and the heel is positioned at the upper end of the blade, that is to say at the peak of dawn.
  • the platform extends transversely between a downstream end, also called a downstream spoiler, and an upstream end, also called an upstream spoiler.
  • the heel extends transversely between an upstream end, also called an upstream spoiler, and a downstream end, also called a downstream spoiler.
  • the role of the platform and the heel is in particular to define the flow stream of the gas flow in the turbine.
  • the blade extends longitudinally between the platform and the heel, and transversely between a leading edge and a trailing edge.
  • Part 41 of cavity 4 forming a platform is provided with a sub-part 411 forming an upstream spoiler of the platform, and with a sub-part 412 forming a downstream spoiler of the platform.
  • the sub-parts forming spoilers 411, 412 have a substantially planar shape and extend substantially in the direction DA.
  • the part 43 of the cavity 4 forming the heel is provided with a sub-part 431 forming the upstream spoiler of the heel (or a first end of the heel), and with a sub-part 432 forming the downstream spoiler of the heel (or a second end heel).
  • the sub-parts 431, 432 forming spoilers are substantially flat.
  • the sub-part 432 forming the downstream spoiler of the heel extends downstream substantially in the direction DA, while the sub-part 431 forming the upstream spoiler extends upstream and is inclined with respect to the direction. DA.
  • Part 43 further comprises sub-parts 433 which extend generally in the direction DR and which are intended to form the wicks of the blade.
  • the filling of the cavity 4 is effected by its upper part at the level of part 43, the filling pipes from cup 2 of installation 1 are shown in dotted lines on the figure 2 .
  • the mold 3 comprises an auxiliary grain duct 5 comprising a first portion 51 and a second portion 52 extending the first portion 51.
  • the first 51 and second 52 portions of the duct 5 are in fluid communication with one another. the other.
  • the first portion 51 opens at a lower end 511 in the part 40 of the cavity 3 forming a foot, and at an upper end 512 in the sub-part 412 forming the downstream spoiler of the platform.
  • the second portion 52 opens at a lower end 521 in the sub-part 412, here at the same location as the first portion 51, and at an upper end 522 in the sub-part 432 forming the downstream spoiler of the heel.
  • the first portion 51 of the duct 5 extends, at its lower end 511, from a downstream wall 401 of the part 40 of the cavity 4.
  • the first portion 51 extends to starting from the downstream wall 401, forming an angle ⁇ therewith of approximately 60 °, this angle ⁇ may be between 54 ° and 62 °.
  • the first portion 51 describes a curved or rounded shape between the part 40 and the sub-part 412.
  • the second portion 52 of the duct 5 extends, at its lower end 521, from the sub-part 412 forming the downstream spoiler of the platform.
  • the second portion 52 extends from the sub-part 412 forming an angle ⁇ therewith of approximately 115 °, this angle ⁇ may be between 110 ° and 115 °.
  • the second portion 52 extends from the subpart 432 forming the downstream spoiler of the heel.
  • the second portion 54 extends from the subpart 432 forming an angle ⁇ of approximately 115 ° therewith, this angle ⁇ may also be between 110 ° and 115 °.
  • the second portion 52 may at least partially have a circular section of diameter D.
  • the second portion 52 may have portions 523 which are remote from the portion 42 of the cavity 3 forming a blade by a distance L
  • the portions 523 are here substantially rectilinear.
  • the second portion 52 has, at the level of a middle part thereof, a necking 524, corresponding to a local reduction in the diameter of the second portion 52. This necking may subsequently allow easier rupture of the latter. the second portion 52 of the duct 5 after directed solidification of the metal, in order to reduce the stresses imposed on the molded vane.
  • the first portion 51 may have at its upper end 512 a weight 513 visible on the figure 1 .
  • the second portion 52 may have, at its lower end 521 and at its upper end 522, two weights 525 and 526 ( figure 1 ).
  • the weights correspond to an enlargement of the portions 51, 52 of the duct 5 at the level of the spoilers 412, 432. As indicated previously, these weights 513, 525, 526 can make it possible to reduce the appearance of porosities in the spoilers of the molded blade. . In fact, the weights make it possible to improve the supply of liquid metal to the parts of the cavity 4 forming the spoilers of the blade, which modifies the cooling isotherms in these parts and reduces the formation of porosities during solidification.
  • the duct 5 is positioned on the downstream side of the cavity 4 (that is to say in particular connected to the sub-parts 412, 432 forming downstream spoilers), it is however possible to envisage making it. position on the upstream side by connecting it in particular to the sub-parts 411, 431 forming upstream spoilers.
  • the figures 3 and 4 respectively show the mold 3 presented above as well as a mold 3 'according to another embodiment of the invention.
  • the molds 3, 3 ' are shown fitted with their ceramic shell 7.
  • the ceramic shells of the molds 3 and 3' are produced according to the same operating mode in order to be able to be compared.
  • the auxiliary grain duct 5 'of the mold 3' has a first portion 51 'which is rectilinear and extends with an angle strictly less than 54 ° from part 40, this angle here being of the order of 45 ° .
  • the duct 5 ' has a second portion 52' which extends the first portion 51 'and which extends from the sub-part 412 forming the downstream spoiler of the platform with an angle of the order of 90 °.
  • the geometry of duct 5 of mold 3 makes it possible to obtain a thickness e of ceramic shell 7 at the level of the wall of the part 42 located opposite the duct 5 which is less than the thickness e ' obtained for the mold 3' ( figure 4 ).
  • This difference in thickness is made possible by virtue of the optimized shape of the duct 5, presented above, with respect to the duct 5 ′.
  • the geometry of the first duct 51 makes it possible to obtain an empty space 70 between the first duct 51 and the part 40; whereas in the mold 3 ′, the geometry of the first duct 51 ′ can cause this space to be filled with ceramic and form a thicker ceramic shell.
  • reducing the thickness of the ceramic shell makes it possible to further reduce the stresses exerted on the molded blade, and the possible appearance of recrystallized grains following a heat treatment.
  • the installation 1 which has been described above can be made entirely of ceramic material, for example by a lost wax casting process.
  • a wax model of the installation 1 must first of all be manufactured. Then, this wax model is covered with a ceramic shell by successive tempering in a suitable slip (tempering / stucco). The ceramic is then fired and the wax removed to obtain the installation 1 in ceramic material.
  • the figure 5 illustrates the main steps of a process for manufacturing a molded part from a molten metal using an installation 1 such as that described above.
  • the first step E1 of the process consists in filling the mold 3, 3 'of the installation 1 by pouring molten metal into the installation. To do this, the metal can be poured directly into the cup 2 of the installation 1, and it can travel by gravity until the mold 3, 3 'is filled.
  • the second step E2 consists in carrying out the directed solidification of the metal present in the mold, so as to obtain the molded blade.
  • the directed solidification is carried out in a suitable furnace in which the installation is placed.
  • the furnace makes it possible to control the growth of the crystalline grains, in order to obtain a single crystal blade thanks to the presence of a grain selector duct 6 or of a single crystal seed.
  • the shell may have already started to break by the end of directed solidification. Once the part has solidified, it can be unchecked. It is then possible to cut out the parts connected to the blade corresponding in particular to the auxiliary grain duct 5, 5 '.
  • a last step E3 consisting of a heat treatment which makes it possible in particular to dissipate the residual stresses in the molded part.
  • the heat treatment may for example consist in subjecting the blade to a temperature between 1270 ° C and 1330 ° C for a period of between 18 hours and 23 hours. Thanks to the use of a mold 3, 3 'according to the invention, a reduction in the appearance of recrystallized grains following this step has been observed.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Turbine Rotor Nozzle Sealing (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)

Description

Arrière-plan de l'inventionBackground of the invention

La présente invention se rapporte au domaine général des procédés de fabrication de pièces par fonderie. L'invention concerne plus particulièrement un moule pour fabriquer une aube de turbomachine monocristalline par fonderie à la cire perdue.The present invention relates to the general field of processes for manufacturing parts by casting. The invention relates more particularly to a mold for manufacturing a single crystal turbomachine blade by lost wax casting.

Dans certains cas, et notamment dans les turbomachines aéronautiques, il est nécessaire de disposer de pièces métalliques ou en alliage métallique qui présentent une structure monocristalline contrôlée. Par exemple, dans les distributeurs de turbines de turbomachines aéronautiques, les aubes doivent supporter des contraintes thermomécaniques importantes dues à la température élevée et aux efforts centrifuges auxquels elles sont soumises. Une structure monocristalline contrôlée dans les alliages métalliques formant ces aubes permet de limiter les effets de ces contraintes.In certain cases, and in particular in aeronautical turbomachines, it is necessary to have metal parts or metal alloy parts which have a controlled monocrystalline structure. For example, in the distributors of turbines of aeronautical turbomachines, the blades must withstand significant thermomechanical stresses due to the high temperature and to the centrifugal forces to which they are subjected. A controlled monocrystalline structure in the metal alloys forming these blades makes it possible to limit the effects of these stresses.

Pour réaliser une pièce métallique de ce type, on connait les procédés du type fonderie à la cire perdue. De façon connue en soi, dans un tel procédé, on réalise tout d'abord un modèle en cire de la pièce à fabriquer, autour duquel on forme une carapace céramique formant un moule. Un métal fondu est ensuite coulé dans le moule, et la solidification dirigée du métal permet d'obtenir, après retrait du moule, la pièce moulée. Ce procédé est avantageux pour fabriquer des pièces métalliques de formes complexes, et permet d'obtenir des pièces ayant une structure monocristalline en utilisant par exemple un germe ou un conduit sélecteur de grain.To produce a metal part of this type, we know the processes of the lost wax casting type. In a manner known per se, in such a process, a wax model of the part to be manufactured is first produced, around which a ceramic shell is formed, forming a mold. A molten metal is then poured into the mold, and the directed solidification of the metal makes it possible to obtain, after removal from the mold, the molded part. This process is advantageous for manufacturing metal parts of complex shapes, and makes it possible to obtain parts having a monocrystalline structure by using, for example, a seed or a grain selector duct.

Les aubes sont généralement constituées d'un pied, d'une plateforme munie de becquets, d'une pale, d'un talon muni de becquets, et de léchettes. Lors de la fabrication d'aubes monocristallines par un procédé tel que celui présenté plus haut, certains problèmes apparaissent, dus notamment à la forme des aubes.The blades generally consist of a foot, a platform fitted with spoilers, a blade, a heel fitted with spoilers, and wipers. During the manufacture of monocrystalline blades by a process such as that presented above, certain problems appear, due in particular to the shape of the blades.

Lors de la solidification dirigée du métal fondu présent dans le moule ayant la forme de l'aube, les parties de la cavité du moule formant notamment les becquets de la plateforme et du talon se solidifient avec un certain retard par rapport aux autres parties de la cavité comme celle formant la pale. Ce retard peut entraîner l'apparition de porosités indésirables dans la pièce finale.During the directed solidification of the molten metal present in the mold having the shape of the blade, the parts of the mold cavity forming in particular the spoilers of the platform and the heel solidify with a some delay with respect to other parts of the cavity such as that forming the blade. This delay can lead to the appearance of undesirable porosities in the final part.

En outre, il a été observé qu'à l'issue d'un traitement thermique réalisé après la solidification dirigée, l'aube peut présenter à certains endroits et notamment sur le bord d'attaque ou le bord de fuite à proximité de la plateforme ou du talon, des grains recristallisés parasites. Cela n'est pas souhaitable lorsque l'on souhaite obtenir une aube monocristalline.In addition, it has been observed that at the end of a heat treatment carried out after the directed solidification, the blade can present in certain places and in particular on the leading edge or the trailing edge near the platform. or of the heel, parasitic recrystallized grains. This is not desirable when it is desired to obtain a single crystal blade.

Enfin, les aubes obtenues peuvent présenter une variation importante de dimensions entre le modèle en cire et la pièce finale, et peuvent parfois être déformées ou vrillées.Finally, the blades obtained can exhibit a significant variation in dimensions between the wax model and the final part, and can sometimes be deformed or twisted.

Des exemples de préparation de moules pour la fabrication d'aubes de turbomachines selon des procédés de l'art antérieur sont par exemple décrits dans les documents EP2 092 996 , WO2014/195634 , WO 2014/135782 , DE 100 33 688 , EP 2 223 755 ou US 5 489 194 .Examples of preparation of molds for the manufacture of turbine engine blades according to methods of the prior art are for example described in documents EP2 092 996 , WO2014 / 195634 , WO 2014/135782 , DE 100 33 688 , EP 2 223 755 Where US 5,489,194 .

Il existe donc un besoin pour disposer d'un moule pour la fabrication d'une aube de turbomachine, ainsi que d'un procédé de fabrication d'une telle aube qui réduise l'apparition des défauts précités.There is therefore a need to have a mold for manufacturing a turbomachine blade, as well as a process for manufacturing such a blade which reduces the appearance of the aforementioned defects.

Objet et résumé de l'inventionPurpose and summary of the invention

La présente invention a donc pour but principal de pallier de tels inconvénients en proposant un moule en matériau céramique destiné à être utilisé pour mouler une aube de turbomachine à partir d'un métal fondu, l'aube comprenant un pied, une plateforme, une pale, et un talon, le moule comprenant :

  • une cavité ayant la forme de l'aube, et
  • un conduit de grain auxiliaire comprenant une première portion et une deuxième portion prolongeant la première portion, ladite première portion débouchant à une extrémité dans une première partie de la cavité formant le pied de l'aube et à une autre extrémité dans une deuxième partie de la cavité formant un becquet de la plateforme de l'aube, ladite deuxième portion débouchant à une extrémité dans ladite deuxième partie de la cavité et à une autre extrémité dans une troisième partie de la cavité formant un becquet du talon de l'aube.
The main object of the present invention is therefore to alleviate such drawbacks by proposing a mold made of ceramic material intended to be used for molding a turbomachine blade from a molten metal, the blade comprising a root, a platform, a blade. , and a heel, the mold comprising:
  • a cavity in the shape of a blade, and
  • an auxiliary grain duct comprising a first portion and a second portion extending the first portion, said first portion opening at one end into a first part of the cavity forming the root of the blade and at another end into a second part of the cavity forming a spoiler of the platform of the blade, said second portion opening at one end into said second part of the cavity and at another end into a third part of the cavity forming a spoiler of the heel of the blade.

La présence du conduit de grain auxiliaire dans le moule selon l'invention permet de minimiser les défauts introduits précédemment. Tout d'abord, le conduit de grain auxiliaire permet de s'assurer que la plateforme et le talon de l'aube ne se solidifient pas en dernier, ce qui réduit l'apparition de défauts du type porosités dans ces portions de l'aube.The presence of the auxiliary grain duct in the mold according to the invention makes it possible to minimize the defects introduced previously. First of all, the auxiliary grain duct ensures that the platform and the heel of the vane do not solidify last, which reduces the appearance of porosity-type defects in these portions of the vane. .

Ensuite, le conduit de grain auxiliaire joue le rôle d'un hauban qui maintient l'aube et la rigidifie tout au long du procédé de fabrication. En la maintenant ainsi, les contraintes résiduelles qui peuvent subsister dans l'aube sont réduites, et l'apparition de grains recristallisés après un traitement thermique est également diminuée.Then, the auxiliary grain duct acts as a stay which holds the vane and stiffens it throughout the manufacturing process. By maintaining it in this way, the residual stresses which may remain in the vane are reduced, and the appearance of recrystallized grains after heat treatment is also reduced.

Les Inventeurs ont observé que l'aube obtenue avec un moule selon l'invention présente des dimensions qui sont plus proches de celles souhaitées, par rapport à une aube fabriquée dans un moule dépourvu de conduit de grain auxiliaire. Les Inventeurs ont également observé que l'aube obtenue est moins vrillée lorsqu'elle est fabriquée dans un moule selon l'invention.The inventors have observed that the blade obtained with a mold according to the invention has dimensions which are closer to those desired, compared to a blade manufactured in a mold without an auxiliary grain duct. The inventors have also observed that the blade obtained is less twisted when it is manufactured in a mold according to the invention.

Le conduit de grain auxiliaire peut être positionné en face du bord d'attaque ou du bord de fuite de l'aube.The auxiliary grain duct can be positioned opposite the leading edge or the trailing edge of the vane.

Les caractéristiques suivantes relatives au conduit auxiliaire de grain permettent encore de limiter l'épaisseur de la carapace céramique, ce qui lui permet de rompre plus facilement et ainsi de réduire l'apparition de grains recristallisés :

  • la première portion du conduit de grain auxiliaire s'étend à partir d'une paroi de la première partie de la cavité dans une direction formant un angle compris entre 54° et 62° avec ladite paroi,
  • la deuxième portion du conduit de grain auxiliaire s'étend à partir de la deuxième partie de la cavité dans une direction formant un angle compris entre 110° et 115° avec ladite deuxième partie,
  • la deuxième portion du conduit de grain auxiliaire s'étend à partir de la troisième partie de la cavité dans une direction formant un angle compris entre 110° et 115° avec ladite troisième partie.
The following characteristics relating to the auxiliary grain duct make it possible to further limit the thickness of the ceramic shell, which allows it to break more easily and thus reduce the appearance of recrystallized grains:
  • the first portion of the auxiliary grain duct extends from a wall of the first part of the cavity in a direction forming an angle of between 54 ° and 62 ° with said wall,
  • the second portion of the auxiliary grain duct extends from the second part of the cavity in a direction forming an angle between 110 ° and 115 ° with said second part,
  • the second portion of the auxiliary grain duct extends from the third part of the cavity in a direction forming an angle between 110 ° and 115 ° with said third part.

Dans un exemple de réalisation, toujours pour limiter l'épaisseur de la carapace céramique et permettre à celle-ci de rompre encore plus facilement et réduire l'apparition de grains recristallisés, la deuxième portion du conduit de grain auxiliaire peut présenter au moins une partie ayant une section circulaire de diamètre D, ladite partie étant éloignée d'une distance L de la cavité, un rapport R=L/D entre la distance L et le diamètre D étant compris entre 16,4 et 18,9 le long de ladite partie.In an exemplary embodiment, still to limit the thickness of the ceramic shell and allow the latter to break even more easily and reduce the appearance of recrystallized grains, the second portion of the auxiliary grain duct may have at least one part. having a circular section of diameter D, said part being spaced by a distance L from the cavity, a ratio R = L / D between the distance L and the diameter D being between 16.4 and 18.9 along said part.

Pour réduire encore l'apparition de porosités au niveau de la plateforme et du talon, la deuxième portion du conduit de grain auxiliaire peut comprendre une masselotte à chacune de ses extrémités. La première portion peut comprendre une masselotte à une extrémité.To further reduce the appearance of porosities at the level of the platform and the heel, the second portion of the auxiliary grain duct may include a weight at each of its ends. The first portion may include a flyweight at one end.

L'aube peut être une aube de turbine de turbomachine aéronautique.The blade may be a blade for an aircraft turbomachine turbine.

Pour faciliter le démoulage de l'aube, la deuxième portion du conduit auxiliaire de grain peut présenter une striction, c'est-à-dire un rétrécissement local de sa section, par exemple au niveau du milieu de ladite deuxième portion. En effet, le conduit auxiliaire de grain pourra rompre plus facilement au niveau de cette striction lors du démoulage.To facilitate demoulding of the blade, the second portion of the auxiliary grain duct may have a necking, that is to say a local narrowing of its section, for example at the level of the middle of said second portion. In fact, the auxiliary grain duct will be able to break more easily at the level of this necking during demolding.

L'invention vise également une installation pour fabriquer une aube moulée à partir d'un métal fondu, comprenant un moule tel que celui présenté précédemment, et des moyens d'obtention de grain monocristallin reliés au moule.The invention also relates to an installation for manufacturing a blade molded from a molten metal, comprising a mold such as that presented above, and means for obtaining monocrystalline grain connected to the mold.

Les moyens d'obtention de grain monocristallin peuvent comprendre un germe monocristallin ou un conduit sélecteur de grain.The means for obtaining monocrystalline grain can comprise a monocrystalline seed or a grain selector duct.

L'invention vise enfin un procédé de fabrication d'une aube de turbomachine monocristalline, comprenant les étapes suivantes :

  • le remplissage d'un moule d'une installation telle que celle présenté précédemment avec un métal fondu, et
  • la solidification dirigée du métal présent dans le moule de façon à obtenir une aube moulée.
Finally, the invention relates to a method of manufacturing a single crystal turbomachine blade, comprising the following steps:
  • filling a mold of an installation such as that presented above with a molten metal, and
  • the directed solidification of the metal present in the mold so as to obtain a molded blade.

Le procédé peut comprendre en outre une étape de traitement thermique de l'aube obtenue. Ce traitement thermique permet de relaxer les contraintes résiduelles à l'intérieur de l'aube moulée qui peuvent être dues notamment au moulage et à la solidification du métal, afin d'obtenir une microstructure stable et des propriétés mécaniques contrôlées dans la pièce finale.The method may further comprise a step of heat treatment of the blade obtained. This heat treatment makes it possible to relax the residual stresses inside the molded blade which may be due in particular to the molding and to the solidification of the metal, in order to obtain a stable microstructure and controlled mechanical properties in the final part.

Brève description des dessinsBrief description of the drawings

D'autres caractéristiques et avantages de la présente invention ressortiront de la description faite ci-dessous, en référence aux dessins annexés qui en illustrent des exemples de réalisation dépourvus de tout caractère limitatif. Sur les figures :

  • la figure 1 est une vue en perspective d'une installation selon l'invention,
  • la figure 2 est une vue en coupe d'un moule selon un mode de réalisation de l'invention,
  • les figures 3 et 4 sont des vues en coupe de moules selon différents modes de réalisation de l'invention, et
  • la figure 5 est un ordinogramme représentant les principales étapes d'un procédé de fabrication d'une aube monocristalline selon un mode de réalisation de l'invention.
Other characteristics and advantages of the present invention will emerge from the description given below, with reference to the drawings. appended which illustrate exemplary embodiments thereof without any limiting nature. In the figures:
  • the figure 1 is a perspective view of an installation according to the invention,
  • the figure 2 is a sectional view of a mold according to one embodiment of the invention,
  • the figures 3 and 4 are sectional views of molds according to different embodiments of the invention, and
  • the figure 5 is a flowchart representing the main steps of a method for manufacturing a monocrystalline blade according to one embodiment of the invention.

Description détaillée de l'inventionDetailed description of the invention

La figure 1 montre une installation 1 pour fabriquer par fonderie une aube de turbine de turbomachine aéronautique monocristalline selon l'invention. L'installation 1 comprend un godet 2 par lequel un métal fondu peut être versé, le godet 2 est configuré pour remplir avec ce métal un moule 3 comprenant une cavité 4 ayant ici la forme d'une aube de turbine de turbomachine aéronautique. Le moule 3 comprend, conformément à l'invention, un conduit de grain auxiliaire 5. Le moule 4 surmonte et est relié à un conduit sélecteur de grain 6 qui permet d'obtenir une aube monocristalline après une solidification dirigée du métal présent dans le moule 3. On notera que l'installation représentée sur la figure 1 est prévue pour fabriquer une seule aube, il est bien entendu envisageable de disposer d'une installation pour fabriquer une pluralité d'aubes.The figure 1 shows an installation 1 for manufacturing by foundry a single crystal aeronautical turbomachine turbine blade according to the invention. The installation 1 comprises a cup 2 through which a molten metal can be poured, the cup 2 is configured to fill with this metal a mold 3 comprising a cavity 4 having here the shape of a blade of an aircraft turbomachine turbine. The mold 3 comprises, in accordance with the invention, an auxiliary grain duct 5. The mold 4 surmounts and is connected to a grain selector duct 6 which makes it possible to obtain a monocrystalline blade after a directed solidification of the metal present in the mold. 3. Note that the installation shown in figure 1 is intended to manufacture a single blade, it is of course conceivable to have an installation for manufacturing a plurality of blades.

La figure 2 montre une vue en coupe de la cavité 4 du moule 3 à laquelle est relié le conduit auxiliaire de grain 5. On notera que sur les figures 1 et 2, pour plus de lisibilité, la paroi en matériau céramique de l'installation 1 et du moule 3 n'a pas été représentée ; en d'autres termes, ces figures montrent seulement les parties internes de l'installation 1 ou du moule 3 dans lesquelles un métal fondu peut être introduit.The figure 2 shows a sectional view of the cavity 4 of the mold 3 to which is connected the auxiliary grain duct 5. It will be noted that on the figures 1 and 2 , for greater readability, the ceramic material wall of the installation 1 and of the mold 3 has not been shown; in other words, these figures show only the internal parts of the installation 1 or of the mold 3 into which a molten metal can be introduced.

Dans tout l'exposé, les termes « inférieur » et « supérieur » sont définis par rapport à la direction DR, la flèche de la direction DR pointant vers l'extérieur. Les termes « amont » et « aval » sont définis par rapport à la direction DA, la flèche de la direction DA pointant vers l'aval. En d'autres termes, l'amont et l'aval sont définis par rapport à la direction d'écoulement du flux gazeux autour de l'aube lorsque l'aube est montée dans une turbomachine.Throughout the description, the terms “lower” and “upper” are defined with respect to the direction DR, the arrow of the direction DR pointing outwards. The terms “upstream” and “downstream” are defined with respect to the direction DA, the arrow of the direction DA pointing downstream. In other words, upstream and downstream are defined in relation to the direction flow of the gas flow around the blade when the blade is mounted in a turbomachine.

La cavité 4 présente la forme d'une aube de turbine de turbomachine aéronautique et comprend : une partie 40 formant le pied de l'aube, une partie 41 formant la plateforme de l'aube, une partie 42 formant la pale de l'aube, et une partie 43 formant le talon de l'aube. La partie 40 formant pied est reliée au niveau de son fond au conduit sélecteur de grain 6. De façon connue en soi, l'aube s'étend longitudinalement entre un pied et un sommet. Dans l'aube moulée, la plateforme est positionnée du côté de l'extrémité inférieure de la pale, entre le pied et la pale, et le talon est positionné à l'extrémité supérieure de la pale, c'est-à-dire au sommet de l'aube. La plateforme s'étend transversalement entre une extrémité aval, aussi appelée becquet aval, et une extrémité amont, aussi appelée becquet amont. Le talon s'étend transversalement entre une extrémité amont, aussi appelée becquet amont, et une extrémité aval, aussi appelée becquet aval. La plateforme et le talon ont notamment pour rôle de définir la veine d'écoulement du flux gazeux dans la turbine. La pale s'étend longitudinalement entre la plateforme et le talon, et transversalement entre un bord d'attaque et un bord de fuite.The cavity 4 has the shape of an aeronautical turbomachine turbine blade and comprises: a part 40 forming the root of the blade, a part 41 forming the platform of the blade, a part 42 forming the blade of the blade , and a part 43 forming the heel of the blade. The part 40 forming the root is connected at its bottom to the grain selector duct 6. In a manner known per se, the blade extends longitudinally between a root and a top. In the molded vane, the platform is positioned on the side of the lower end of the blade, between the root and the blade, and the heel is positioned at the upper end of the blade, that is to say at the peak of dawn. The platform extends transversely between a downstream end, also called a downstream spoiler, and an upstream end, also called an upstream spoiler. The heel extends transversely between an upstream end, also called an upstream spoiler, and a downstream end, also called a downstream spoiler. The role of the platform and the heel is in particular to define the flow stream of the gas flow in the turbine. The blade extends longitudinally between the platform and the heel, and transversely between a leading edge and a trailing edge.

La partie 41 de la cavité 4 formant plateforme est pourvue d'une sous-partie 411 formant un becquet amont de la plateforme, et d'une sous-partie 412 formant un becquet aval de la plateforme. Les sous-parties formant becquets 411, 412 ont une forme sensiblement plane et s'étendent sensiblement selon la direction DA.Part 41 of cavity 4 forming a platform is provided with a sub-part 411 forming an upstream spoiler of the platform, and with a sub-part 412 forming a downstream spoiler of the platform. The sub-parts forming spoilers 411, 412 have a substantially planar shape and extend substantially in the direction DA.

La partie 43 de la cavité 4 formant talon est pourvue d'une sous-partie 431 formant becquet amont du talon (ou une première extrémité du talon), et d'une sous-partie 432 formant becquet aval du talon (ou une deuxième extrémité du talon). Les sous-parties 431, 432 formant becquets son sensiblement planes. La sous-partie 432 formant le becquet aval du talon s'étend vers l'aval sensiblement selon la direction DA, alors que la sous-partie 431 formant le becquet amont s'étend vers l'amont et est inclinée par rapport à la direction DA. La partie 43 comprend en outre des sous-parties 433 qui s'étendent généralement selon la direction DR et qui sont destinées à former les léchettes de l'aube. Le remplissage de la cavité 4 est effectué par sa partie supérieure au niveau de la partie 43, les conduits de remplissage à partir du godet 2 de l'installation 1 sont représentés en pointillés sur la figure 2.The part 43 of the cavity 4 forming the heel is provided with a sub-part 431 forming the upstream spoiler of the heel (or a first end of the heel), and with a sub-part 432 forming the downstream spoiler of the heel (or a second end heel). The sub-parts 431, 432 forming spoilers are substantially flat. The sub-part 432 forming the downstream spoiler of the heel extends downstream substantially in the direction DA, while the sub-part 431 forming the upstream spoiler extends upstream and is inclined with respect to the direction. DA. Part 43 further comprises sub-parts 433 which extend generally in the direction DR and which are intended to form the wicks of the blade. The filling of the cavity 4 is effected by its upper part at the level of part 43, the filling pipes from cup 2 of installation 1 are shown in dotted lines on the figure 2 .

Conformément à l'invention, le moule 3 comprend un conduit de grain auxiliaire 5 comprenant une première portion 51 et une deuxième portion 52 prolongeant la première portion 51. Les première 51 et deuxième 52 portions du conduit 5 sont en communication fluidique l'une avec l'autre. La première portion 51 débouche à une extrémité inférieure 511 dans la partie 40 de la cavité 3 formant pied, et à une extrémité supérieure 512 dans la sous-partie 412 formant becquet aval de la plateforme. La deuxième portion 52 débouche à une extrémité inférieure 521 dans la sous-partie 412, ici au même endroit que la première portion 51, et à une extrémité supérieure 522 dans la sous-partie 432 formant becquet aval du talon.According to the invention, the mold 3 comprises an auxiliary grain duct 5 comprising a first portion 51 and a second portion 52 extending the first portion 51. The first 51 and second 52 portions of the duct 5 are in fluid communication with one another. the other. The first portion 51 opens at a lower end 511 in the part 40 of the cavity 3 forming a foot, and at an upper end 512 in the sub-part 412 forming the downstream spoiler of the platform. The second portion 52 opens at a lower end 521 in the sub-part 412, here at the same location as the first portion 51, and at an upper end 522 in the sub-part 432 forming the downstream spoiler of the heel.

La première portion 51 du conduit 5 s'étend, au niveau de son extrémité inférieure 511, à partir d'une paroi aval 401 de la partie 40 de la cavité 4. Dans l'exemple illustré, la première portion 51 s'étend à partir de la paroi aval 401 en formant un angle α avec celle-ci d'environ 60°, cet angle α peut être compris entre 54° et 62°. La première portion 51 décrit une forme courbe ou arrondie entre la partie 40 et la sous-partie 412.The first portion 51 of the duct 5 extends, at its lower end 511, from a downstream wall 401 of the part 40 of the cavity 4. In the example illustrated, the first portion 51 extends to starting from the downstream wall 401, forming an angle α therewith of approximately 60 °, this angle α may be between 54 ° and 62 °. The first portion 51 describes a curved or rounded shape between the part 40 and the sub-part 412.

La deuxième portion 52 du conduit 5 s'étend, au niveau de son extrémité inférieure 521, à partir de la sous-partie 412 formant becquet aval de la plateforme. Dans l'exemple illustré, la deuxième portion 52 s'étend à partir de la sous-partie 412 en formant un angle β avec celle-ci d'environ 115°, cet angle β peut être compris entre 110° et 115°. A son extrémité supérieure 522, la deuxième portion 52 s'étend à partir de la sous-partie 432 formant becquet aval du talon. Dans l'exemple illustré, la deuxième portion 54 s'étend à partir de la sous-partie 432 en formant un angle γ d'environ 115° avec celle-ci, cet angle γ peut être également compris entre 110° et 115°.The second portion 52 of the duct 5 extends, at its lower end 521, from the sub-part 412 forming the downstream spoiler of the platform. In the example illustrated, the second portion 52 extends from the sub-part 412 forming an angle β therewith of approximately 115 °, this angle β may be between 110 ° and 115 °. At its upper end 522, the second portion 52 extends from the subpart 432 forming the downstream spoiler of the heel. In the example illustrated, the second portion 54 extends from the subpart 432 forming an angle γ of approximately 115 ° therewith, this angle γ may also be between 110 ° and 115 °.

La deuxième portion 52 peut présenter au moins en partie une section circulaire de diamètre D. Dans l'exemple illustré, la deuxième portion 52 peut présenter des portions 523 qui sont éloignées de la partie 42 de la cavité 3 formant pale d'une distance L. Les portions 523 sont ici sensiblement rectilignes. Le rapport R=L/D peut, le long de ces portions 523, être compris entre 16,4 et 18,9.The second portion 52 may at least partially have a circular section of diameter D. In the example illustrated, the second portion 52 may have portions 523 which are remote from the portion 42 of the cavity 3 forming a blade by a distance L The portions 523 are here substantially rectilinear. The ratio R = L / D can, along these portions 523, be between 16.4 and 18.9.

Dans l'exemple illustré, la deuxième portion 52 présente au niveau d'une partie médiane de celle-ci, une striction 524, correspondant à une diminution locale du diamètre de la deuxième portion 52. Cette striction peut permettre ultérieurement une rupture plus facile de la deuxième portion 52 du conduit 5 après solidification dirigée du métal, afin de réduire les contraintes imposées à l'aube moulée.In the example illustrated, the second portion 52 has, at the level of a middle part thereof, a necking 524, corresponding to a local reduction in the diameter of the second portion 52. This necking may subsequently allow easier rupture of the latter. the second portion 52 of the duct 5 after directed solidification of the metal, in order to reduce the stresses imposed on the molded vane.

La première portion 51 peut présenter au niveau de son extrémité supérieure 512 une masselotte 513 visible sur la figure 1. La deuxième portion 52 peut présenter au niveau de son extrémité inférieure 521 et au niveau de son extrémité supérieure 522 deux masselottes 525 et 526 (figure 1). Les masselottes correspondent à un élargissement des portions 51, 52 du conduit 5 au niveau des becquets 412, 432. Comme indiqué précédemment, ces masselottes 513, 525, 526 peuvent permettre de réduire l'apparition de porosités dans les becquets de l'aube moulée. En effet, les masselottes permettent d'améliorer l'alimentation en métal liquide des parties de la cavité 4 formant becquets de l'aube, ce qui modifie les isothermes de refroidissement dans ces parties et réduit la formation de porosités lors de la solidification.The first portion 51 may have at its upper end 512 a weight 513 visible on the figure 1 . The second portion 52 may have, at its lower end 521 and at its upper end 522, two weights 525 and 526 ( figure 1 ). The weights correspond to an enlargement of the portions 51, 52 of the duct 5 at the level of the spoilers 412, 432. As indicated previously, these weights 513, 525, 526 can make it possible to reduce the appearance of porosities in the spoilers of the molded blade. . In fact, the weights make it possible to improve the supply of liquid metal to the parts of the cavity 4 forming the spoilers of the blade, which modifies the cooling isotherms in these parts and reduces the formation of porosities during solidification.

On notera que, dans l'exemple illustré, le conduit 5 est positionné du côté aval de la cavité 4 (c'est-à-dire notamment relié aux sous-parties 412, 432 formant becquets avals), il est toutefois envisageable de le positionner du côté amont en le reliant notamment aux sous-parties 411, 431 formant becquets amont.It will be noted that, in the example illustrated, the duct 5 is positioned on the downstream side of the cavity 4 (that is to say in particular connected to the sub-parts 412, 432 forming downstream spoilers), it is however possible to envisage making it. position on the upstream side by connecting it in particular to the sub-parts 411, 431 forming upstream spoilers.

On notera également que les caractéristiques préférées concernant les angles α, β et γ, ainsi que le rapport R ont été illustrées sur un même moule 3, mais peuvent ne pas être appliquées simultanément.It will also be noted that the preferred characteristics concerning the angles α, β and γ, as well as the ratio R have been illustrated on the same mold 3, but may not be applied simultaneously.

Les figures 3 et 4 montrent respectivement le moule 3 présenté précédemment ainsi qu'un moule 3' selon un autre mode de réalisation de l'invention. Sur ces figures, les moules 3, 3' sont représentés munis de leur carapace en céramique 7. Les carapaces céramiques des moules 3 et 3' sont réalisées selon un même mode opératoire pour pouvoir être comparées.The figures 3 and 4 respectively show the mold 3 presented above as well as a mold 3 'according to another embodiment of the invention. In these figures, the molds 3, 3 'are shown fitted with their ceramic shell 7. The ceramic shells of the molds 3 and 3' are produced according to the same operating mode in order to be able to be compared.

Le conduit de grain auxiliaire 5' du moule 3' présente une première portion 51' qui est rectiligne et s'étend avec un angle strictement inférieur à 54° à partir de la partie 40, cet angle est ici de l'ordre de 45°. Le conduit 5' présente une deuxième portion 52' qui prolonge la première portion 51' et qui s'étend à partir de la sous-partie 412 formant becquet aval de la plateforme avec un angle de l'ordre de 90°.The auxiliary grain duct 5 'of the mold 3' has a first portion 51 'which is rectilinear and extends with an angle strictly less than 54 ° from part 40, this angle here being of the order of 45 ° . The duct 5 'has a second portion 52' which extends the first portion 51 'and which extends from the sub-part 412 forming the downstream spoiler of the platform with an angle of the order of 90 °.

On peut voir que la géométrie du conduit 5 du moule 3 (figure 3) permet d'obtenir une épaisseur e de carapace céramique 7 au niveau de la paroi de la partie 42 située en face du conduit 5 qui est inférieure à l'épaisseur e' obtenue pour le moule 3' (figure 4). Cette différence d'épaisseur est rendue possible grâce à la forme optimisée du conduit 5, présentée précédemment, par rapport au conduit 5'. En outre, dans le moule 3, on peut voir que la géométrie du premier conduit 51 permet d'obtenir un espace vide 70 entre le premier conduit 51 et la partie 40 ; alors que dans le moule 3', la géométrie du premier conduit 51' peut entrainer le comblement de cet espace par de la céramique et former une carapace céramique plus épaisse. Comme expliqué précédemment, la réduction de l'épaisseur de la carapace céramique permet de réduire encore les contraintes exercées sur l'aube moulée, et l'apparition éventuelle de grains recristallisés suite à un traitement thermique.It can be seen that the geometry of duct 5 of mold 3 ( figure 3 ) makes it possible to obtain a thickness e of ceramic shell 7 at the level of the wall of the part 42 located opposite the duct 5 which is less than the thickness e ' obtained for the mold 3' ( figure 4 ). This difference in thickness is made possible by virtue of the optimized shape of the duct 5, presented above, with respect to the duct 5 ′. In addition, in the mold 3, it can be seen that the geometry of the first duct 51 makes it possible to obtain an empty space 70 between the first duct 51 and the part 40; whereas in the mold 3 ′, the geometry of the first duct 51 ′ can cause this space to be filled with ceramic and form a thicker ceramic shell. As explained above, reducing the thickness of the ceramic shell makes it possible to further reduce the stresses exerted on the molded blade, and the possible appearance of recrystallized grains following a heat treatment.

L'installation 1 qui a été décrite précédemment peut être réalisée entièrement en matériau céramique, par exemple par un procédé de fonderie à la cire perdue. De façon connue en soi, un modèle de l'installation 1 en cire doit tout d'abord être fabriqué. Puis, ce modèle en cire est recouvert d'une carapace de céramique par trempes successives dans une barbotine adéquate (trempe/stucage). La céramique est ensuite cuite et la cire retirée pour obtenir l'installation 1 en matériau céramique.The installation 1 which has been described above can be made entirely of ceramic material, for example by a lost wax casting process. In a manner known per se, a wax model of the installation 1 must first of all be manufactured. Then, this wax model is covered with a ceramic shell by successive tempering in a suitable slip (tempering / stucco). The ceramic is then fired and the wax removed to obtain the installation 1 in ceramic material.

La figure 5 illustre les principales étapes d'un procédé de fabrication d'une pièce moulée à partir d'un métal fondu mettant en œuvre une installation 1 telle que celle décrite précédemment. La première étape E1 du procédé consiste à remplir le moule 3, 3' de l'installation 1 en versant un métal fondu dans l'installation. Pour ce faire, on peut verser le métal directement dans le godet 2 de l'installation 1, et il pourra cheminer par gravité jusqu'à remplir le moule 3, 3'.The figure 5 illustrates the main steps of a process for manufacturing a molded part from a molten metal using an installation 1 such as that described above. The first step E1 of the process consists in filling the mold 3, 3 'of the installation 1 by pouring molten metal into the installation. To do this, the metal can be poured directly into the cup 2 of the installation 1, and it can travel by gravity until the mold 3, 3 'is filled.

La deuxième étape E2 consiste à réaliser la solidification dirigée du métal présent dans le moule, de façon à obtenir l'aube moulée. La solidification dirigée est réalisée dans un four adapté dans lequel on place l'installation. Le four permet de contrôler la croissance des grains cristallisés, afin d'obtenir une aube monocristalline grâce à la présence d'un conduit sélecteur de grain 6 ou d'un germe monocristallin. La carapace peut avoir déjà commencé à rompre dès la fin de la solidification dirigée. Une fois la pièce solidifiée, on peut la décocher. On peut ensuite découper les parties reliées à l'aube correspondant notamment au conduit auxiliaire de grain 5, 5'.The second step E2 consists in carrying out the directed solidification of the metal present in the mold, so as to obtain the molded blade. The directed solidification is carried out in a suitable furnace in which the installation is placed. The furnace makes it possible to control the growth of the crystalline grains, in order to obtain a single crystal blade thanks to the presence of a grain selector duct 6 or of a single crystal seed. The shell may have already started to break by the end of directed solidification. Once the part has solidified, it can be unchecked. It is then possible to cut out the parts connected to the blade corresponding in particular to the auxiliary grain duct 5, 5 '.

Enfin, il est possible de réaliser une dernière étape E3 consistant en un traitement thermique qui permet notamment de dissiper les contraintes résiduelles dans la pièce moulée. Pour une aube en superalliage du type AM1, le traitement thermique peut par exemple consister à soumettre l'aube à une température comprise entre 1270°C et 1330°C pendant une durée comprise entre 18 heures et 23 heures. Grâce à l'emploi d'un moule 3, 3' selon l'invention, une réduction de l'apparition de grains recristallisés suite à cette étape a été observée.Finally, it is possible to carry out a last step E3 consisting of a heat treatment which makes it possible in particular to dissipate the residual stresses in the molded part. For an AM1 type superalloy blade, the heat treatment may for example consist in subjecting the blade to a temperature between 1270 ° C and 1330 ° C for a period of between 18 hours and 23 hours. Thanks to the use of a mold 3, 3 'according to the invention, a reduction in the appearance of recrystallized grains following this step has been observed.

Dans tout l'exposé, les termes « compris entre ... et ... » doivent être compris comme incluant les bornes.Throughout the description, the terms "between ... and ..." must be understood as including the limits.

Claims (7)

  1. A ceramic material mold (3; 3') for use in molding a turbine engine blade from a molten metal, the blade comprising a root, an inner platform, an airfoil, and an outer platform, and the mold comprising:
    - a cavity (4) having the shape of the blade; and
    - an auxiliary grain duct (5, 5') comprising a first segment (51; 51') and a second segment (52; 52') extending the first segment, said first segment opening out at one end (511) into a first portion (40) of the cavity forming the root of the blade, and at another end (512) into a second portion (412) of the cavity forming a lip of the inner platform of the blade, said second segment (52; 52') opening out at one end (521) into said second portion (412) of the cavity, and at another end (522) into a third portion (432) of the cavity forming a lip of the outer platform of the blade;
    wherein the first segment (51) of the auxiliary grain duct (5) extends from a wall (401) of the first portion (40) of the cavity (4) in a direction that forms an angle (α) lying in the range 54° to 62° with said wall;
    wherein the second segment (52) of the auxiliary grain duct (5) extends from the second portion (412) of the cavity (4) in a direction forming an angle (β) lying in the range 110° to 115° with said second portion; and
    wherein the second segment (52) of the auxiliary grain duct (5) extends from the third portion (432) of the cavity (4) in a direction forming an angle (γ) lying in the range 110° to 115° with said third portion.
  2. A mold (3) according to claim 1, wherein the second segment (52) of the auxiliary grain duct (5) presents at least one portion (523) having a circular section of diameter D, said portion being spaced apart from the cavity by a distance L, the ratio R=L/D between the distance L and the diameter D lying in the range 16.4 to 18.9 along said portion.
  3. A mold (3) according to claim 1 or claim 2, wherein the second segment (52) of the auxiliary grain duct (5) includes a feeder (525, 526) at each of its ends.
  4. A mold according to any one of claims 1 to 3, wherein the blade is a turbine blade for an aviation turbine engine.
  5. An installation (1) for fabricating a blade molded from a molten metal, the installation comprising:
    - a mold (3; 3') according to any one of claims 1 to 4; and
    - monocrystalline grain obtaining means (6) connected to the mold.
  6. An installation (1) according to claim 5, wherein the monocrystalline grain obtaining means comprise a monocrystalline seed or a grain selector duct (6).
  7. A method of fabricating a monocrystalline turbine engine blade, the method comprising the following steps:
    - filling (E1) a mold (3; 3') of an installation (1) according to claim 5 or claim 6 with a molten metal; and
    - directionally solidifying (E2) the metal present in the mold (3; 3') so as to obtain a molded blade.
EP17733496.8A 2016-06-02 2017-06-01 Mould for manufacturing a single-crystal blade by casting, installation and method of manufacture implementing same Active EP3463714B1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
FR1655021A FR3052088B1 (en) 2016-06-02 2016-06-02 MOLD FOR THE MANUFACTURE OF A MONOCRYSTALLINE DARK BY FOUNDRY, INSTALLATION AND METHOD OF MANUFACTURING THE SAME
PCT/FR2017/051371 WO2017207933A1 (en) 2016-06-02 2017-06-01 Mould for manufacturing a single-crystal blade by casting, installation and method of manufacture implementing same

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EP3463714A1 EP3463714A1 (en) 2019-04-10
EP3463714B1 true EP3463714B1 (en) 2021-09-29

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US (1) US10576535B2 (en)
EP (1) EP3463714B1 (en)
CN (1) CN109219489B (en)
BR (1) BR112018074832B1 (en)
CA (1) CA3025331C (en)
FR (1) FR3052088B1 (en)
RU (1) RU2730827C2 (en)
WO (1) WO2017207933A1 (en)

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CN109226691A (en) * 2018-10-10 2019-01-18 深圳市万泽中南研究院有限公司 Manufacturing method, ceramic shell mould and the manufacturing equipment of guide vane
CN109940131B (en) * 2019-03-26 2020-09-18 中国科学院金属研究所 Method for reducing formation of internal porosity defect of single crystal high temperature alloy blade tenon
FR3094655B1 (en) * 2019-04-08 2021-02-26 Safran A method of manufacturing a plurality of distributor sectors by foundry
CN113070454A (en) * 2021-03-16 2021-07-06 贵阳航发精密铸造有限公司 Casting device and method for non-preferred orientation single crystal guide hollow blade
FR3127022A1 (en) 2021-09-15 2023-03-17 Safran Aircraft Engines Dawn including added spoilers

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Publication number Priority date Publication date Assignee Title
US5489194A (en) * 1990-09-14 1996-02-06 Hitachi, Ltd. Gas turbine, gas turbine blade used therefor and manufacturing method for gas turbine blade
DE10033688B4 (en) * 2000-07-11 2008-04-24 Alstom Technology Ltd. Process for the production of directionally solidified castings
RU2239520C1 (en) * 2003-03-21 2004-11-10 Федеральное государственное унитарное предприятие "Всероссийский научно-исследовательский институт авиационных материалов" Apparatus for making casting of monocrystalline turbine blade
FR2927270B1 (en) * 2008-02-08 2010-10-22 Snecma PROCESS FOR MANUFACTURING DIRECTED SOLIDIFICATION AUBES
US7918265B2 (en) * 2008-02-14 2011-04-05 United Technologies Corporation Method and apparatus for as-cast seal on turbine blades
GB0901663D0 (en) * 2009-02-04 2009-03-11 Rolls Royce Plc Casting method
FR3002870B1 (en) * 2013-03-07 2015-03-06 Snecma PROCESS FOR PRODUCING A ROTOR BLADE FOR A TURBOMACHINE
FR3006616B1 (en) * 2013-06-05 2016-03-04 Snecma TURBOMACHINE WAVE PREFORM

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CN109219489A (en) 2019-01-15
RU2018146438A (en) 2020-07-10
CN109219489B (en) 2020-10-30
EP3463714A1 (en) 2019-04-10
US20190337048A1 (en) 2019-11-07
FR3052088A1 (en) 2017-12-08
FR3052088B1 (en) 2018-06-22
CA3025331C (en) 2023-10-03
RU2018146438A3 (en) 2020-07-10
WO2017207933A1 (en) 2017-12-07
RU2730827C2 (en) 2020-08-26
BR112018074832A2 (en) 2019-03-06
BR112018074832B1 (en) 2022-08-02
US10576535B2 (en) 2020-03-03
CA3025331A1 (en) 2017-12-07

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