EP3487649B1 - Procede de fabrication de moule carapace - Google Patents

Procede de fabrication de moule carapace Download PDF

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Publication number
EP3487649B1
EP3487649B1 EP17754752.8A EP17754752A EP3487649B1 EP 3487649 B1 EP3487649 B1 EP 3487649B1 EP 17754752 A EP17754752 A EP 17754752A EP 3487649 B1 EP3487649 B1 EP 3487649B1
Authority
EP
European Patent Office
Prior art keywords
model
process according
slip
powder
contact
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Active
Application number
EP17754752.8A
Other languages
German (de)
English (en)
French (fr)
Other versions
EP3487649A1 (fr
Inventor
Wen Zhang
Patrice Henri Claude RAGOT
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
Original Assignee
Safran Aircraft Engines SAS
Safran SA
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Publication date
Application filed by Safran Aircraft Engines SAS, Safran SA filed Critical Safran Aircraft Engines SAS
Publication of EP3487649A1 publication Critical patent/EP3487649A1/fr
Application granted granted Critical
Publication of EP3487649B1 publication Critical patent/EP3487649B1/fr
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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C1/00—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds
    • B22C1/02—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by additives for special purposes, e.g. indicators, breakdown additives
    • B22C1/04—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by additives for special purposes, e.g. indicators, breakdown additives for protection of the casting, e.g. against decarbonisation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C1/00—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds
    • B22C1/16—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by the use of binding agents; Mixtures of binding agents
    • B22C1/165—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by the use of binding agents; Mixtures of binding agents in the manufacture of multilayered shell moulds
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C1/00—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds
    • B22C1/02—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by additives for special purposes, e.g. indicators, breakdown additives
    • B22C1/08—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by additives for special purposes, e.g. indicators, breakdown additives for decreasing shrinkage of the mould, e.g. for investment casting
    • 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

Definitions

  • the present invention relates to the manufacture of a foundry mold in a so-called “lost wax” process, for the manufacture of precision metal parts.
  • This type of mold is also called a shell mold.
  • a model of the part to be manufactured is first produced in wax or in a removable material which can be melted or easily removed from the manufactured mold.
  • the model is successively soaked, sandblasted and / or coated with a reinforcement and dried.
  • the quenching operation is carried out in one or more slip (s).
  • the sandblasting operation also called stuccoing, consists in reinforcing the deposit formed by the layer of slip deposited on the model during quenching.
  • the water is removed from the various layers.
  • the model is eliminated for example during a passage in an autoclave (treatment by pressure and temperature).
  • the mold undergoes a heat treatment in order to give it the characteristics necessary for the casting of the metal.
  • a mold For the fabrication of precision metal parts, a mold must be stable when casting molten metal.
  • stable is meant that the molten metal must not cause the mold material to react in such a way that the latter deforms.
  • the composition of the first layer in contact with the model commonly called the contact layer, is chemically compatible and closely matches the profile of the model. .
  • This contact layer is the result of soaking the model in a contact slip.
  • the contact layer must be homogeneous, stable, fluid, dense, non-reactive with the molten metal of the precision part to be manufactured and compatible with the following layers of the mold.
  • the expansion coefficients of the contact layer and of the following layers constituting the mold must be compatible so as to avoid any damage caused by a difference in thermal expansion of the layers.
  • alumina is not compatible with certain alloys that make up the precision metal parts to be produced
  • electro-fused silica lacks refractoriness
  • zircon in addition to being radioactive, loses stability over time. as the temperature of the molten alloy increases.
  • the document GB 2 017 118 describes a method of making a shell mold.
  • the document JP H06 15404 describes a self-collapsing casting mold.
  • the document EP 0 479 672 describes a shell mold usable in lost wax casting.
  • the document EP 2 153 919 describes a shell mold and a method of making shell molds.
  • the object of the invention is in particular to provide a simple, effective and economical solution to these problems.
  • the invention proposes a method of manufacturing a shell mold with several layers, including at least one contact layer, from a model of a part to be manufactured in wax or other material. similar, the method comprising a step of dipping the model in a contact slip forming the contact layer and comprising a binder and a powder, the powder comprising a mullite-zirconia composite.
  • mullite-zirconia composite powder makes it possible to limit the chemical interactions between the shell mold and the metal alloy introduced by casting into the shell mold.
  • the aforementioned composite is preferably essentially or almost exclusively formed of mullite and zirconia. Obviously, it is understood that it could include impurities in negligible quantity. These impurities can be calcium or sodium, in particular.
  • the binder can be inorganic or organic or even be a mixture of organic and inorganic compounds.
  • the mullite-zirconia composite powder makes it possible in particular to produce a contact slip having good rheological stability, good chemical inertia with respect to the molten alloy and the manufacture of which is controlled.
  • a composite is a material composed of several elementary components, the association of which confers on all the properties that none of the components taken separately possesses.
  • the mullite-zirconia composite powder can be obtained by chemical synthesis using a mullite precursor such as alumina and / or silica and a zirconia precursor such as zircon. The grains of the powder are then formed from an aggregate of mullite and zirconia.
  • the grains of the mullite-zirconia composite powder have an average size of between 5 and 20 ⁇ m and a size distribution ranging from a submicron size up to a size of 100 ⁇ m.
  • the contact layer may have a thickness less than or equal to 1 mm. It is desirable to limit the thickness of the contact layer to avoid mechanically weakening the shell mold due to the presence of zirconia.
  • the level of zirconia in the powder is between 5% and 90% by weight and, preferably between 10% and 50% by weight, and even more preferably between 30% and 50%.
  • the binder is colloidal silica.
  • the contact slip also comprises at least one wetting agent and / or at least one anti-foaming agent.
  • the steps of soaking in the second slip, coating in the reinforcing material and drying the model coated with the reinforcing material and dried are repeated.
  • the phase of producing the contact slip also comprises a sub-step of adding the anti-foaming agent and / or the wetting agent.
  • the invention also relates to the use of a mold according to the method which has just been described, for the manufacture of a cast and solidified turbomachine part.
  • the mold 1, schematically shown in section on the figure 2 comprises a plurality of layers 2, 3, 4, 5, superimposed on each other and covering a model 6 made of wax or a similar material, that is to say a material having similar characteristics and easily removable.
  • the method for making the mold 1 comprises steps 100 to 700 which will now be described.
  • a first step 100 the model 6, in wax, of the precision part to be manufactured is produced.
  • the model 6 is made to the exact dimensions of the precision part and includes a high quality exterior surface finish 7.
  • a finishing pass i.e. a machining operation
  • the model 6 will have a surface condition such that a finishing pass will not be necessary and the precision part can be used directly on leaving the mold.
  • a contact layer 2 which may have a thickness less than or equal to 1 mm.
  • the contact layer 2 has an essential role in the use of the mold 1 since it is this which will give the precision part produced its outer surface. It is thus necessary for the contact slip to be dense and resistant at the same time, and for its viscosity and its covering power to be controlled.
  • Viscosity and density are necessary so that during dipping, the contact slip perfectly matches the wax model 6, and more precisely the outer surface 7 of the wax model 6 without creating, between the contact slip and the surface 7 exterior of the model 6, of air bubbles which would form, on an internal surface 8 of the mold 1, a cavity conducive to the creation of roughness on the exterior surface of the precision part.
  • the resistance of the contact slip will be necessary, so that the contact layer 2 does not deform during the manufacture of the precision part.
  • the contact slip is composed of an inorganic and / or organic binder and of a powder, in this case a mullite-zirconia composite.
  • the binder is an inorganic colloidal binder such as colloidal silica in an amount by mass of between 10% and 40% and, preferably, between 20% and 30%.
  • the inorganic binder can be sodium silicate or else ethyl silicate and the organic binder comprises water.
  • the powder comprises, by weight, a zirconia content of between 5% and 90% and, preferably, between 10% and 50% and even more preferably between 30% and 50%.
  • the mass distribution is given here by way of example, it being understood that a variation of the mass distribution of between 0.1% and 10% is possible.
  • the other additives which can be added can be a bactericidal agent to limit bacteria and increase the stability of the slip, or other organic binders making it possible to guarantee a uniform and resistant deposit of the contact layer 2 on model 6 in wax.
  • the contact slip also comprises a wetting agent and an anti-foaming agent.
  • the mixture in the quenching tank is then the contact slip.
  • composition of the contact slip has many advantages over the slip of the prior art, among which a better shelf life, good chemical stability, reduced manufacturing time, a non-radioactive formulation and an increased quality of the material. mold obtained.
  • a third step 300 the model 6 soaked in the contact slip, is sandblasted and then dried.
  • the sandblasting is carried out in a not very aggressive with a powder which will not affect the contact layer 2 and in particular the condition of the internal surface 8 of the mold 1.
  • Sanding makes it possible in particular to reinforce the contact layer 2 and to facilitate the attachment of a second layer of the mold 1.
  • a fourth step 400 the model 6 surrounded by the sandblasted and dried contact layer 2 is dipped in a second slip which may be of the same composition as the contact slip or of a different composition.
  • a fifth step 500 the model, taken out of the second slip, is sandblasted and then dried.
  • a model 6 is obtained on which the contact layer 2 and a first reinforcing layer 3 are superimposed.
  • steps 400 and 500 can be repeated as a function of the thickness to be given to the mold 1.
  • this example of a mold 1 is in no way limiting and a greater or lesser number of reinforcing layers 3 could be provided.
  • a sixth step 600 the wax model 6 is melted so that only the mold 1 remains.
  • a seventh (and last) step 700 the mold 1, comprising an adequate number of reinforcing layers (here three reinforcing layers 3, 4, 5) undergoes a heat treatment, in this case baking in an oven. , in order to solidify the mold 1.
  • a heat treatment in this case baking in an oven.
  • the removal of the wax model 6 (also called the dewaxing step) is carried out before the heat treatment of the mold 1. It is also possible that the wax model 6 is removed during the step. 700 heat treatment, the temperature for consolidating the mold 1 being sufficient to melt the wax of the model 6, the steps 600 and 700 then being combined in a single step.
  • a material for example a metal alloy for the manufacture of the blades, can be cast in the mold 1, against the internal surface 8. After cooling, this cast material then forms the part. precision to manufacture.
  • the mold 1 can be removed mechanically (breaking the mold 1), chemically (dissolving the mold 1), or by a mechanical and chemical combination.
  • contact layer 2 presents a low (if any) risk of chemical reaction with a wide variety of materials which can be cast to form the contact. precision part.
  • the mullite-zirconia composite ensures good ease of implementation of the slip and makes it possible to cover the 6 models in wax with complex geometries and in particular to be housed in the grooves and other inaccessible cavities so that all the details 6 wax models are reproduced on the contact layer 2.
  • the mullite-zirconia composite offers the advantage of not being radioactive, and therefore easy to handle without specific equipment.
  • FIGS. 3 and 4 represent two images obtained by scanning electron microscopy of the grains of two different mullite-zirone composites which can both be used in the process according to the invention.
  • the mullite-zirconia composite can be obtained by fusion synthesis ( figure 3 ) or by synthesis by reactive sintering in the solid state ( figure 4 ) followed in either case by solidification by cooling.
  • the blocks of mullite-zirconia composite obtained then undergo micronization or ultra-fine grinding.
  • the figure 5 is a schematic illustration of several grains of a mullite-zirconia composite powder showing the diversity of grain shapes.
  • the grains of the mullite-zirconia composite powder have an average size of between 5 and 20 ⁇ m and a size distribution ranging from a submicron size up to a size of 100 ⁇ m.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Mold Materials And Core Materials (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
EP17754752.8A 2016-07-22 2017-07-21 Procede de fabrication de moule carapace Active EP3487649B1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
FR1657022A FR3054149B1 (fr) 2016-07-22 2016-07-22 Procede de fabrication de moule carapace
PCT/FR2017/052030 WO2018015701A1 (fr) 2016-07-22 2017-07-21 Procede de fabrication de moule carapace

Publications (2)

Publication Number Publication Date
EP3487649A1 EP3487649A1 (fr) 2019-05-29
EP3487649B1 true EP3487649B1 (fr) 2021-09-22

Family

ID=57796407

Family Applications (1)

Application Number Title Priority Date Filing Date
EP17754752.8A Active EP3487649B1 (fr) 2016-07-22 2017-07-21 Procede de fabrication de moule carapace

Country Status (8)

Country Link
US (1) US10987723B2 (pt)
EP (1) EP3487649B1 (pt)
CN (1) CN109475928B (pt)
BR (1) BR112019001244B1 (pt)
CA (1) CA3031321A1 (pt)
FR (1) FR3054149B1 (pt)
RU (1) RU2753188C2 (pt)
WO (1) WO2018015701A1 (pt)

Family Cites Families (13)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4196769A (en) * 1978-03-20 1980-04-08 Remet Corporation Ceramic shell mold
FR2667523B1 (fr) * 1990-10-03 1993-07-09 Snecma Moule carapace soluble pour fonderie et procede d'elimination.
JP2718460B2 (ja) * 1991-01-16 1998-02-25 工業技術院長 易崩壊性鋳型及びその製造方法
US5927379A (en) * 1996-09-26 1999-07-27 Pcc Structurals, Inc. Infiltration method for producing shells useful for investment casting
US6814131B2 (en) * 2000-11-10 2004-11-09 Buntrock Industries, Inc. Investment casting mold and method of manufacture
DE60311824T2 (de) * 2002-08-20 2007-10-31 Ex One Corp. Giessverfahren
US6951239B1 (en) * 2004-04-15 2005-10-04 United Technologies Corporation Methods for manufacturing investment casting shells
DE102007012660B4 (de) * 2007-03-16 2009-09-24 Chemex Gmbh Kern-Hülle-Partikel zur Verwendung als Füllstoff für Speisermassen
CN101301677A (zh) * 2008-06-03 2008-11-12 西安交通大学 一种复杂零件快速精密铸造方法
US8033320B2 (en) * 2008-07-25 2011-10-11 General Electric Company High emittance shell molds for directional casting
CN102527937A (zh) * 2012-03-15 2012-07-04 哈尔滨工业大学 一种钛合金熔模铸造用纤维增强薄壁型壳的制备方法
CN104550736A (zh) * 2013-10-22 2015-04-29 青岛五洋铸机有限公司 用于钛及钛合金精密铸造的氮化硼陶瓷型壳的制备方法
CN105039751B (zh) * 2015-07-30 2017-09-26 何明亮 锆合金用接触材料、采用该材料的过滤介质和浇道的制备方法

Also Published As

Publication number Publication date
RU2019103466A3 (pt) 2020-12-07
RU2019103466A (ru) 2020-08-24
CN109475928A (zh) 2019-03-15
US10987723B2 (en) 2021-04-27
BR112019001244B1 (pt) 2022-08-09
CN109475928B (zh) 2022-01-07
US20190329317A1 (en) 2019-10-31
FR3054149A1 (fr) 2018-01-26
RU2753188C2 (ru) 2021-08-12
WO2018015701A1 (fr) 2018-01-25
BR112019001244A2 (pt) 2019-04-30
FR3054149B1 (fr) 2019-04-05
CA3031321A1 (fr) 2018-01-25
EP3487649A1 (fr) 2019-05-29

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