EP3475012B1 - Four de refroidissement par solidification dirigée et procédé de refroidissement utilisant un tel four - Google Patents

Four de refroidissement par solidification dirigée et procédé de refroidissement utilisant un tel four Download PDF

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Publication number
EP3475012B1
EP3475012B1 EP17745799.1A EP17745799A EP3475012B1 EP 3475012 B1 EP3475012 B1 EP 3475012B1 EP 17745799 A EP17745799 A EP 17745799A EP 3475012 B1 EP3475012 B1 EP 3475012B1
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EP
European Patent Office
Prior art keywords
zone
cooling
casting
furnace
temperature
Prior art date
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Application number
EP17745799.1A
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German (de)
English (en)
French (fr)
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EP3475012A1 (fr
Inventor
Ngadia Taha NIANE
Serge Fargeas
Said BOUKERMA
Serge Tenne
Gilles Martin
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.)
Safran Aircraft Engines SAS
Safran SA
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Safran Aircraft Engines SAS
Safran SA
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Publication of EP3475012A1 publication Critical patent/EP3475012A1/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
    • B22D27/00—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting
    • B22D27/04—Influencing the temperature of the metal, e.g. by heating or cooling the mould
    • B22D27/045—Directionally solidified castings

Definitions

  • the present invention relates to the field of cooling metal parts manufactured by foundry, more particularly a cooling furnace by directed solidification for a metal part found in the foundry, and a method of cooling by directed solidification of a metal part in the foundry using such a furnace.
  • lost wax or lost pattern foundry processes are particularly suitable for the production of metal parts of complex shapes.
  • the lost-model foundry is used in particular for the production of turbine engine blades.
  • the first step is the production of a model in a material with a comparatively low melting temperature, such as for example a wax or resin, on which a mold is then overmolded.
  • a material with a comparatively low melting temperature such as for example a wax or resin
  • the material is evacuated from inside the mold.
  • a molten metal is then poured into this mold, in order to fill the cavity formed by the model in the mold after its evacuation.
  • the mold can be opened or destroyed in order to recover a metal part that conforms to the shape of the model.
  • each model being connected to a shaft which forms, in the mold, pouring channels for the molten metal.
  • metal is meant in the present context, both pure metals and metal alloys.
  • directed solidification is meant in the present context, the control of the germination and the growth of solid crystals, in a given direction, in the molten metal during its formation. change from liquid to solid.
  • the object of such directed solidification is to avoid the negative effects of grain boundaries in the part.
  • the directed solidification can be columnar or monocrystalline.
  • Columnar directed solidification consists in orienting all the grain boundaries in the same direction, so as to reduce their contribution to the propagation of cracks.
  • Monocrystalline directed solidification consists in ensuring the solidification of the part into a single crystal, so as to eliminate grain boundaries.
  • the parts produced by directed solidification can achieve not only particularly high mechanical strengths in all axes of force, but also improved thermal strength, since additives intended to bind the crystal grains more strongly together can be dispensed with.
  • these metal parts thus produced can be advantageously used, for example, in the hot parts of turbines.
  • a liquid metal is cast in a mold comprising a central barrel extending, along a main axis, between a casting cup and a base, and a plurality of mold cavities arranged in a cluster around of the central barrel, each connected to the casting bucket by a supply channel.
  • this molten metal is gradually cooled, along said main axis from the base towards the casting cup. This can be achieved, for example, by gradually extracting the mold from an oven or a heating chamber, along the main axis, downwards, while cooling the base.
  • the solidification of the metal begins near the base and extends from it in a direction parallel to the main axis.
  • thermomechanical stresses generated can be the cause of the formation of recrystallized grains and cracks. during the solidification and cooling of these blades, thus creating areas of weakness of the final part.
  • the wall of the furnace defining the internal enclosure has a section of any shape which may be circular, square or hexagonal along a plane perpendicular to the central vertical axis of the furnace.
  • the shape of the oven can also have a generally oblong section.
  • the mold support can be a plate which can move vertically along the central axis of the furnace and is able to support the mold in which the liquid metal is to be poured.
  • the casting zone designates the zone of the internal enclosure of the furnace in which the casting of the liquid metal in the mold takes place.
  • the mold support is then positioned at the bottom of this casting zone or between the casting zone and the cooling zone, so that the mold, placed on the mold support, is also placed in this zone.
  • the cooling zone designates the zone of the internal enclosure of the furnace positioned vertically under the casting zone in which, when the mold is positioned in this cooling zone, the liquid metal present in the mold after casting. gradually cools and solidifies.
  • the terms “above”, “below”, “top”, “bottom”, “under” are defined with respect to the direction of the metal being poured into the mold under the effect of force of gravity, that is, relative to the normal orientation of the mold and the cooling furnace when the metal is poured into the mold.
  • the casting and cooling zones have a first and a second heater, respectively, so that the temperature of the casting zone is higher than the temperature of the cooling zone.
  • the fact that the temperature of the cooling zone is lower than the temperature of the casting zone allows the metal in the mold to gradually change from the liquid state to the solid state.
  • the two zones are thermally insulated from each other by a first fixed heat shield which can be placed in the wall of the furnace, and by a second heat shield carried by the mold support when the latter is placed in the zone of the oven. casting, allowing the temperature of each zone to be regulated more precisely, without it being influenced by the temperature of the neighboring zone.
  • the regulation of the heating devices, and therefore of the temperature of the casting and cooling zones makes it possible to control the temperatures, the cooling rate and therefore the temperature gradients during the cooling of the metal, and thus limit thermomechanical stresses and plastic deformations in the metal.
  • the upper part of the cooling zone comprising the second heating device makes it possible to control the temperature gradients in the metal during the directed solidification.
  • the third heat shield can be placed in the wall of the furnace. The upper part of the cooling zone is thus thermally insulated from the casting zone by the first and the second heat shield, and from the lower part of the cooling zone by the third heat shield, which makes it possible to regulate the heat more precisely. temperature of this zone, without it being influenced by the temperature of neighboring zones.
  • the upper part of the cooling zone is removable.
  • the second heater includes an induction susceptor.
  • the second heater includes an electrical resistance.
  • the internal enclosure has a diameter greater than or equal to 20 cm, preferably greater than or equal to 50 cm, more preferably greater than or equal to 80 cm.
  • the casting zone comprises an upper part and a lower part thermally insulated from each other by a fourth heat shield, the upper part comprising a top heating device and the lower part comprising a control device. low heating.
  • the top and bottom heaters of the casting zone are configured so that the temperature of the upper part is greater than or equal to the temperature of the lower part.
  • the top and bottom heaters of the casting zone are configured so that the temperature of the lower part is greater than or equal to the temperature of the upper part.
  • the temperature difference between the casting zone and the liquid metal is between 0 ° C and 50 ° C, the temperature of the casting zone being lower than the temperature of the liquid metal.
  • the temperature of the upper part of the cooling zone is greater than or equal to 700 ° C, preferably greater than or equal to 800 ° C, more preferably greater than or equal to 900 ° C.
  • the cooling rate at a given point of the metal part is less than - 0.30 ° C / s, preferably less than or equal to - 0.25 ° C / s, and greater than - 0.10 ° C / s, preferably greater than or equal to - 0.15 ° C / s.
  • Cooling rates have negative values. Indeed, for example, a cooling rate of - 0.30 ° C / s means that during cooling, the temperature at a given point of the metal part decreases by 0.30 ° C every second. Therefore, by "less than - 0.30 ° C / s" is understood a slower cooling rate, so that these values must be considered in absolute value. For example, - 0.25 ° C / s is a cooling rate lower than - 0.30 ° C / s.
  • a first step of this foundry process consists in manufacturing a model of the blade and grouping together a plurality of models so as to form a cluster allowing the manufacture of a mold, described in the following step.
  • a shell mold 1 is made from the wax cluster.
  • the last operation of the second step consists in removing the wax from the cluster model of the shell mold 1. This wax removal is carried out by bringing the shell mold 1 to a temperature above the melting temperature of the wax.
  • the cluster 10 of blades 12 is formed ( Fig. 1 ) in the shell mold 1 by pouring molten metal into the shell mold 1.
  • the metal is poured into the shell mold 1 via the upper part of the mold, called the casting cup 14.
  • the shell mold 1 is located in a casting zone A of the cooling furnace 20.
  • the metal present in the shell mold is cooled and solidified in a cooling zone B of the cooling furnace 20.
  • each of the blades 12 is separated from the rest of the cluster 10 and finished by finishing processes, for example dyeing processes. 'machining.
  • the invention relates in particular to the cooling furnace 20 and to the solidification process implemented during the fourth step indicated above.
  • This solidification process called 'directed solidification' is carried out by means of the furnace 20 ( Fig. 2 ).
  • the oven 20 comprises a cylindrical wall 22 of vertical central axis X, and an upper wall 24 disposed on the upper end of the cylindrical wall 22, perpendicular to the X axis, so that the cylindrical 22 and upper walls 24 form an internal enclosure 26 of the oven.
  • the upper wall has an orifice 240, positioned substantially in the center of the wall 24.
  • the furnace consists of a casting zone A and a cooling zone B, superimposed on each other, so that the casting zone A is arranged above the cooling zone B.
  • the casting A and cooling B zones are thermally insulated from each other by a first heat shield 31, which may be a thermally non-conductive material inserted into the wall 22.
  • the first heat shield 31 may be composed of compressed graphite paper, or a sandwich with a felt layer compressed between two layers of graphite having an emissivity of between 0.4 and 0.8 depending on the temperature (sold for example under the name of PAPEYX).
  • the oven 20 further comprises a horizontal mold support 28, arranged within the internal enclosure 26, and fixed on a jack 29 allowing the support 28 to be moved vertically upwards or downwards.
  • the mold support 28 has a second heat shield 32, so that when the mold 1 is positioned on the mold support 28, the mold 1 is thermally insulated from the rest of the internal enclosure 26 which is located under the second heat shield. 32.
  • the mold 1 is thermally insulated from the cooling zone B by the first heat shield 31 and the second heat shield 32.
  • the cooling zone B itself comprises an upper part B 'and a lower part B ", the upper parts B' and lower B" being superimposed on one another so that the upper part B ' is arranged above the lower part B ".
  • the upper and lower parts B 'and B" are thermally insulated from each other by a third heat shield 33.
  • the upper part B' also comprises a heating device 60 comprising a susceptor 62 and a heating coil 64.
  • the lower part B ", constituting the lower part of the oven 20, is connected to a frame 70.
  • the upper part B 'of the cooling zone B is removable.
  • the heating device 60 can thus be adapted as a function of the parts to be cooled, their dimensions and their alloys. This also makes it possible to simplify and facilitate maintenance operations for the operators.
  • the casting zone A also comprises an upper part A 'and a lower part A ", the upper parts A' and lower A” being superimposed one on the other so that the upper part A 'is arranged at the bottom. above the lower part A ".
  • the upper and lower parts A 'and A" are thermally insulated from each other by a fourth heat shield 34.
  • the upper part A' comprises a heating device 40 comprising a susceptor 42 and a heating coil 44.
  • the susceptor 42 may be a graphite tube disposed in the internal enclosure 26 so as to be pressed against the wall 22 of the furnace 20.
  • the heating coil 44 may be a copper coil surrounding the external wall 22, making it possible to create a magnetic field having the effect of heating the susceptor 42.
  • the latter thus also heats the internal enclosure 26 by radiation.
  • the internal enclosure 26 is placed under vacuum, so as to preserve the graphite susceptor from any oxidation.
  • the internal enclosure 26 can also be placed under a partial vacuum with the presence of neutral gas, for example argon.
  • the lower part A also comprises a heating device 50 comprising a susceptor 52 and a heating coil 54, the heating device 50 of the lower part A" being separate from the heating device 40 of the upper part A ', so in providing heating the parts independently of one another, and thus controlling the temperature gradients in the internal chamber 29 at the level of the casting zone A.
  • the internal diameter of the cylindrical wall is between 200 and 1000 mm.
  • the casting zone extends vertically over a height of 1 m. These dimensions make it possible to work with large clusters, comprising a greater number of blades, the height of which may be between 200 and 300 mm.
  • the removable upper part B ' extends vertically over a height of between 150 and 300 mm.
  • the upper part B 'of the cooling zone is fixed to the oven 20.
  • a casting step consists in placing the mold 1 in the casting zone A by positioning it on the support 28, itself located in the casting zone A.
  • the mold 1 is positioned so that the casting cup 14 is in front of the 'orifice 240 of the upper wall 24 of the furnace 20.
  • the heating devices 40 and 50 are adjusted so as to heat the mold 1 by thermal radiation, so as to maintain the latter at a temperature between 1480 ° C and 1600 ° C.
  • the temperature of the casting zone is therefore less than or equal to the temperature of the liquid metal, the difference being between 0 and 50 ° C.
  • the temperature of the liquid metal cast in the mold 1 remains higher than the melting temperature of the metal, so as to avoid an unwanted solidification of the metal in the mold 1 during the entire casting step.
  • the mold 1 is also thermally insulated from the cooling zone B by the first and second heat shields 31 and 32.
  • the support 28 is then moved downwards by the jack 29, so that the mold gradually passes from the casting zone A to the cooling zone B '( figure 3B ).
  • the temperature of this zone is then adjusted to a temperature of 700 ° C or higher than 700 ° C, while being lower than the melting temperature of the metal so as to cause the solidification of the latter, the casting zone A being always maintained at a temperature of 1500 ° C to 1530 ° C.
  • the lower part of the mold 1 being the first to enter the cooling zone, the liquid metal therefore begins to solidify in this lower part of the mold. This creates a solidification front, represented symbolically by a line 12a on the figure 3B , corresponding to the interface between the liquid and solid phases of the metal.
  • This solidification front 12a moves upwards in the frame of reference of the mold 1, as the latter enters the cooling zone B, according to the principle of directed solidification.
  • the mold 1 is finally located, over its entire height, in the lower part B "of the cooling zone, so that all of the metal present in the mold 1 is at the bottom. solid state.
  • the solidification phase is then completed.
  • the total duration of the cooling process is for example between 3600 and 7600 seconds, the support 28 moving at a speed between 1 and 10mm / s.
  • the blades 12 obtained are hollow or solid and single crystal blades, comprising nickel-based alloys.
  • nickel-based alloy is understood to mean alloys in which the mass content of nickel is predominant. It is understood that nickel is therefore the element with the highest mass content in the alloy.
  • These hollow or solid vanes, which are more fragile, can have defects if the temperature gradients are not controlled during cooling and solidification.
  • the furnace and the process described above, in particular the removable part B ′ make it possible to limit or even eliminate these risks by adjusting the temperature of this part to a sufficiently high temperature (greater than or equal to 700 ° C.), so as to minimize the risks. thermal gradients existing in the blades 12 in the direction of the directed solidification, that is to say when the mold 1 is located both in the casting zone A and in the cooling zone B.
  • the figure 4 illustrates the change in temperature at a point on the leading edge of a blade 12, for different temperatures of the removable part B ', during the solidification phase (S) and the cooling phase (R) .
  • the dotted curve represents the reference case using a copper cooler making it possible to maintain a cooling zone at a temperature of approximately 300 ° C
  • the continuous thin line curve represents a case using the oven when the removable part B 'heats up to 700 ° C
  • the curve in solid bold line represents a case where the removable part B 'heats to 1000 ° C.
  • the other curves represent intermediate cases.
  • the cooling rate corresponding to the slope of the curve, is - 0.23 ° C / s, so that the temperature at this point is 57 ° C higher than in the reference case.
  • the cooling rate is - 0.18 ° C / s, so that the temperature at this point is 165 ° C higher than in the reference case.
  • the figure 5 illustrates the thermal stresses in the metal of a blade by comparing the use of a conventional furnace (blades (b) on the right on the figure 5 ) and a furnace according to the present description (blades (a) on the left on the figure 5 ).
  • the top and bottom blades respectively represent the two main faces of the same blade.
  • the zones 90 indicate the zones of the blade where the stresses are the greatest.
  • the zones 92 indicate the zones of the blade where the stresses are the most important.
  • the zones 92 extend over a smaller surface of the blade than the zones 90, so that the stresses are lower in the blades cooled by the furnace 20 of the present description, than by a conventional furnace. More specifically, the stresses in the metal can be reduced by about 24%, using the furnace 20 and the method of the present disclosure.
  • the cooling zone may include two heaters superimposed on one another.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
  • Waste-Gas Treatment And Other Accessory Devices For Furnaces (AREA)
  • Manufacture And Refinement Of Metals (AREA)
  • Furnace Details (AREA)
EP17745799.1A 2016-06-27 2017-06-27 Four de refroidissement par solidification dirigée et procédé de refroidissement utilisant un tel four Active EP3475012B1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
FR1655959A FR3052991B1 (fr) 2016-06-27 2016-06-27 Four de refroidissement par solidification dirigee et procede de refroidissement utilisant un tel four
PCT/FR2017/051706 WO2018002506A1 (fr) 2016-06-27 2017-06-27 Four de refroidissement par solidification dirigée et procédé de refroidissement utilisant un tel four

Publications (2)

Publication Number Publication Date
EP3475012A1 EP3475012A1 (fr) 2019-05-01
EP3475012B1 true EP3475012B1 (fr) 2021-02-24

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EP17745799.1A Active EP3475012B1 (fr) 2016-06-27 2017-06-27 Four de refroidissement par solidification dirigée et procédé de refroidissement utilisant un tel four

Country Status (8)

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US (1) US10730108B2 (pt)
EP (1) EP3475012B1 (pt)
CN (1) CN109475931B (pt)
BR (1) BR112018077120B1 (pt)
CA (1) CA3029438C (pt)
FR (1) FR3052991B1 (pt)
RU (1) RU2744601C2 (pt)
WO (1) WO2018002506A1 (pt)

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Publication number Priority date Publication date Assignee Title
JP7112638B1 (ja) * 2021-02-24 2022-08-04 株式会社エビス 一方向凝固装置及び一方向凝固方法
CN114589299A (zh) * 2022-03-14 2022-06-07 上海元定科技有限公司 一种用于定向单晶精密铸造炉的保温线圈结构

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SU786142A1 (ru) * 1979-07-20 2005-11-27 М.М. Виноградский Устройство для изготовления отливок
US6209618B1 (en) * 1999-05-04 2001-04-03 Chromalloy Gas Turbine Corporation Spool shields for producing variable thermal gradients in an investment casting withdrawal furnace
JP2009279628A (ja) * 2008-05-23 2009-12-03 Ihi Corp 一方向凝固鋳造装置
US20130022803A1 (en) * 2008-09-25 2013-01-24 General Electric Company Unidirectionally-solidification process and castings formed thereby
RU2398653C1 (ru) * 2009-03-18 2010-09-10 Федеральное государственное унитарное предприятие "Всероссийский научно-исследовательский институт авиационных материалов" (ФГУП "ВИАМ") Устройство для получения отливок с направленной и монокристаллической структурой
RU2492026C1 (ru) * 2012-07-10 2013-09-10 Федеральное государственное унитарное предприятие "Всероссийский научно-исследовательский институт авиационных материалов" (ФГУП "ВИАМ") Устройство для получения отливок с направленной и монокристаллической структурой
FR2995807B1 (fr) * 2012-09-25 2015-10-09 Snecma Moule carapace a ecran thermique
RU2545979C1 (ru) * 2013-10-16 2015-04-10 Рустам Фаритович Мамлеев Устройство для получения отливок направленной кристаллизацией
PL222793B1 (pl) * 2014-03-13 2016-09-30 Seco/Warwick Europe Spółka Z Ograniczoną Odpowiedzialnością Sposób ukierunkowanej krystalizacji odlewów łopatek turbin gazowych oraz urządzenie do wytwarzania odlewów łopatek turbiny gazowej o ukierunkowanej i monokrystalicznej strukturze
CN105568018A (zh) * 2015-07-22 2016-05-11 重庆电子工程职业学院 一种定向凝固镁合金装置及用该装置定向凝固镁合金方法
CN105436478A (zh) * 2015-12-30 2016-03-30 上海大学 控制变截面处杂晶形成的方法

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Also Published As

Publication number Publication date
WO2018002506A1 (fr) 2018-01-04
CN109475931A (zh) 2019-03-15
RU2744601C2 (ru) 2021-03-11
FR3052991A1 (fr) 2017-12-29
EP3475012A1 (fr) 2019-05-01
RU2019101951A3 (pt) 2020-10-05
US20200180019A1 (en) 2020-06-11
CA3029438C (fr) 2024-02-13
FR3052991B1 (fr) 2018-07-27
CN109475931B (zh) 2021-04-13
CA3029438A1 (fr) 2018-01-04
US10730108B2 (en) 2020-08-04
BR112018077120B1 (pt) 2022-07-26
RU2019101951A (ru) 2020-07-28
BR112018077120A2 (pt) 2019-04-30

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