EP3544754B1 - Modèle en forme de grappe et carapace pour obtention d'un accessoire de manutention indépendant de pièces formées et procédé associé - Google Patents

Modèle en forme de grappe et carapace pour obtention d'un accessoire de manutention indépendant de pièces formées et procédé associé Download PDF

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Publication number
EP3544754B1
EP3544754B1 EP17832291.3A EP17832291A EP3544754B1 EP 3544754 B1 EP3544754 B1 EP 3544754B1 EP 17832291 A EP17832291 A EP 17832291A EP 3544754 B1 EP3544754 B1 EP 3544754B1
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EP
European Patent Office
Prior art keywords
shell
elements
casting
central
handling
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
EP17832291.3A
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German (de)
English (en)
French (fr)
Other versions
EP3544754A1 (fr
Inventor
Ngadia Taha NIANE
Ramzi BOHLI
Loïc GALVIN
Saïd BOUKERMA
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 EP3544754A1 publication Critical patent/EP3544754A1/fr
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Publication of EP3544754B1 publication Critical patent/EP3544754B1/fr
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Classifications

    • 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
    • B22C9/043—Removing the consumable pattern
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/02—Sand moulds or like moulds for shaped castings
    • B22C9/04—Use of lost patterns
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C7/00—Patterns; Manufacture thereof so far as not provided for in other classes
    • B22C7/02—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
    • B22D27/045—Directionally solidified castings
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/08—Features with respect to supply of molten metal, e.g. ingates, circular gates, skim gates
    • B22C9/082—Sprues, pouring cups
    • 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
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2230/00—Manufacture
    • F05D2230/20—Manufacture essentially without removing material
    • F05D2230/21—Manufacture essentially without removing material by casting
    • F05D2230/211—Manufacture essentially without removing material by casting by precision casting, e.g. microfusing or investment casting

Definitions

  • the present invention relates to the field of cluster manufacturing of elements, in particular bladed elements, of turbomachines by the lost-wax casting technique.
  • Each element is preferably an individual blade such as a compressor or turbine impeller blade.
  • the invention relates to all types of land or aeronautical turbomachines, and in particular aircraft turbomachines such as turbojets and turboprops.
  • the invention relates to the design of the model in the form of a cluster and that of the shell intended to be formed around this model partially in wax, shell in which the metal is intended to be cast to obtain the elements of turbomachinery.
  • the invention thus proposes a model in the form of a cluster and a shell for obtaining at least an accessory for handling the cluster independent of the formed turbomachine elements, as well as an associated manufacturing method by lost-wax casting of a plurality of turbomachine elements.
  • lost-wax precision casting consists of producing in wax, by injecting into tools, a model of each of the desired bladed elements.
  • the assembly of these models on a wax distributor makes it possible to constitute a model in the shape of a cluster which is then immersed in different substances in order to form around it a ceramic shell of substantially uniform thickness.
  • the cluster-shaped model is also commonly referred to as a "replica”, “cluster-assembly" or even “wax tree", although not all of its components are necessarily made of wax or other sacrificial material.
  • the process is continued by melting the wax, which then leaves its exact imprint in the ceramic shell, into which the molten metal is poured, via a pouring cup assembled on the metal distributor. After the metal has cooled, the shell is destroyed and the metal parts are separated and finished.
  • This technique offers the advantage of dimensional precision, making it possible to reduce or even eliminate certain machining operations. In addition, it offers a very good surface appearance.
  • the principle of drop casting, or gravity, of the molten metal which consists of casting the metal from above into the cavities of the shell intended to form the turbomachine parts.
  • the molten metal is poured into the bucket and then generally reaches an annular system for supplying the plurality of cavities intended to form the turbomachine parts, as described for example in the French patent application FR 2 985 924 A1 .
  • such a supply system can also be used as a handling crown for the cluster at different stages of the manufacturing process, in particular at the exit from the furnace, during shake-out, that is to say during the destruction of the shell, or even during cutting to obtain metal turbomachine parts.
  • the principle of source casting of the molten metal is also known, which consists on the contrary of casting the metal from below into the cavities of the shell intended to form the parts of turbomachinery. Most often, the molten metal is poured into the cup then specific conduits connected to the cup then allow the injection of the metal from the lower part of the cavities.
  • the kinetic energy stored before entering the cavities is greater so that the speed is higher.
  • the metal supply means therefore promote pressure drops and have, for example, a bend to reduce the speed.
  • the cluster for which the source casting principle is applied is provided with a supply system forming a ring for handling the cluster as described previously in connection with the drop casting principle.
  • This handling crown is typically in direct connection with the parts to be formed. So, if the mass of the crown is equivalent to that of the parts, there is a strong risk that the crown will interact mechanically with the parts during solidification and/or during cooling, which can lead to the parts, when the efforts are sufficient, to defects of the crack or core offset type, but also in the case of single-crystal solidification to the generation of recrystallized grains due to the internal stresses generated in the parts.
  • the object of the invention is to remedy at least partially the needs mentioned above and the drawbacks relating to the embodiments of the prior art.
  • the handling accessory in particular in the form of a handling ring, has in the invention a single purpose of handling the bunch, in particular at the exit of the oven, on shakeout and during cutting, and no longer a sighting of molten metal supply as according to the drop casting principle described above.
  • the handling accessory has sufficient mechanical properties not to yield under its own weight during handling and mainly not to fracture during cooling.
  • the cluster-shaped model and the shell according to the invention may also include one or more of the following characteristics taken separately or in any possible technical combination.
  • the handling accessory shell may comprise radial arms fluidically connecting a handling ring shell, centered on the longitudinal axis, to the central descender.
  • the handling accessory shell may comprise a central element with a central axis coinciding with the longitudinal axis of the shell, fixed to the central descender or to the casting bucket, the radial arms fluidically connecting the shell of the handling crown and the central element.
  • the shell elements can advantageously be arranged around the longitudinal axis, being circumferentially spaced from each other, and defining an interior space centered on the longitudinal axis in which the central descendant is located.
  • each shell element can be in fluid communication, at its second upper end part, with a single wax discharge conduit connected to the casting cup.
  • each shell element can be in fluid communication, at its second upper end part, with a single wax evacuation duct.
  • the shell may comprise at least a first set and a second set of a plurality of wax evacuation ducts respectively interconnected by at least a first lateral duct and a second lateral duct, said at least one first lateral duct and a second lateral conduit being respectively fluidically connected with the pouring cup by means of at least a first and a second main wax evacuation conduits extending respectively between the pouring cup and the said at least one first and one second conduits side.
  • the carapace turbomachine elements can for example be bladed carapace elements, each designed to obtain a single moving blade.
  • Another subject of the invention is a process for the manufacture by lost-wax casting of a plurality of elements, in particular bladed elements, of a turbomachine, characterized in that it is placed implemented using a shell as defined previously and/or using a model in the form of a cluster as defined above, the method comprising a step of pouring the metal into the shell.
  • turbomachine elements which may for example be moving compressor or turbine blades, or even compressor or turbine stator blades, produced individually or in sectors comprising several blades.
  • a first embodiment of a shell 1 according to the invention for the manufacture by investment casting of a plurality of turbomachine elements, in particular bladed elements.
  • a cluster-shaped model (not shown) is first made around which the shell 1, preferably made of ceramic, is intended to be formed.
  • This cluster-shaped model is essentially composed of sacrificial elements made of wax, but not exclusively. However, for the sake of simplicity, it is referred to as a "wax pattern”.
  • the implementation of the step of producing the ceramic shell 1 is carried out in known manner by dipping the wax model in successive baths (not shown).
  • the shell 1 obtained has the general shape of a cluster, and comprises shell elements which will be described below, with the shell 1 represented on the figure 1 in a position as adopted afterwards when it is filled with molten metal.
  • the shell 1 firstly comprises a pouring cup 2 of metal, which can be completely or partially covered with the shell 1.
  • This pouring cup 2 is in fluid communication with a central descender 3 extending along the longitudinal axis X of the shell 1.
  • This central descendant 3 preferably takes the form of a hollow cylinder of axis X which extends from the bottom of the casting cup 2 to the level of the lower ends 4a of the bladed shell elements 4.
  • the central descender 3 advantageously communicates, in a manner known per se, with source supply conduits 5, visible on the picture 2 described below, bladed shell elements 4 intended to form the metal parts in the form of bladed elements.
  • the molten metal is injected into the casting cup 2, then passes through the central descender 3 and is injected, in the lower part, into the source supply ducts 5 so as to allow the bladed shell elements to be filled. 4 from below, that is to say from bottom to top.
  • the bladed shell elements 4 are said to be bladed because after removal of the wax replica, they each internally form a cavity corresponding to a blade. These bladed shell elements 4 extend upwards, being arranged around the axis X, and also around the central descender 3 extending along this same axis, downwards from the bottom of the casting bucket 2
  • the bladed shell elements 4 form the peripheral wall of the shell 1, of longitudinal axis X. They are circumferentially spaced from each other, and define an interior space centered on this axis X, space in which is therefore located central 3.
  • the shell 1 comprises a handling accessory shell 6 which is completely independent of the bladed elements of the shell 4 and of their molten metal supply circuit.
  • This handling accessory shell 6 comprises for example a central element 7 of revolutionary shape, cylindrical or conical, with a central axis coinciding with the central axis X of the shell 1, oriented vertically.
  • This central element 7 is fixed to the central descender 3, or even to the casting cup 2 directly.
  • Radial arms 8, more visible on the picture 2 connect the central element 7 to a handling ring shell 9 centered on the axis X.
  • the radial arms 8 and the handling ring shell 9 are for example arranged just below the casting bucket 2.
  • the radial arms 8 and the central element 7 are in fluidic communication with the central descender 3, itself in fluidic communication with the casting cup 2, in order to allow the metal construction of the handling accessory .
  • a drop casting is carried out in order to obtain this handling accessory.
  • the invention implements both casting at the source to allow the formation of the bladed elements of the turbomachine and casting at the drop to allow the formation of the handling accessory, the bladed elements and the handling accessory being thus produced completely independently in order to avoid the appearance of manufacturing defects as explained above.
  • each bladed shell element 4 is in fluid communication, at its upper end 4b, with a single wax evacuation duct 10, also called a wax-puller or even dewaxing vents 10.
  • a single wax evacuation duct 10 also called a wax-puller or even dewaxing vents 10.
  • These wax evacuation ducts 10 are oriented substantially vertically in the position of the shell 1 shown schematically on the figure 1 .
  • FIG 1 also shows that, to reinforce the holding of the shell of the handling crown 9, several ceramic holding reinforcements 11 may be provided connecting the shell of the crown 9 to the casting cup 2.
  • a first 12a, a second 12b, a third 12c and a fourth 12d sets of four wax evacuation ducts 10 respectively associated with four bladed shell elements 4 are each fluidly connected to each other by respectively first 14a, second 14b, third 14c and fourth 14c side ducts.
  • the wax discharge ducts 10 are therefore partly connected to each other in order to make them integral. In this way, it is possible to avoid having excessive vibrations during the shake-out step in particular. Indeed, these vibrations could be very detrimental by causing recrystallization, and therefore the appearance of recrystallized grains on the formed parts.
  • the evacuation of the wax takes place in the pouring cup 2 by means of first 13a, second 13b, third 13c and fourth 13d main wax evacuation ducts, each being fluidly connected to a plurality of bladed shell elements 4.
  • such an embodiment according to the example of figure 2 can improve molding and safety aspects. This can also make it possible to reduce or further increase the stresses in the blade during the solidification phase and a finer evacuation of the wax. In this way, it may therefore be possible to optimize the dewaxing system.
  • shell 1 is preheated to high temperature in a dedicated furnace, for example between 1000 and 1200°C, in order to promote the fluidity of the metal in the shell 1 during casting.
  • a dedicated furnace for example between 1000 and 1200°C
  • the molten metal therefore successively borrows the casting cup 2, then the central descender 3, the central element 7, the radial arms 8 and the crown shell 9 to form the handling accessory in falling casting, and almost simultaneously the central downcomer 3, the source supply ducts 5 and the shell bladed elements 4 to form the turbomachine bladed elements by source casting.
  • the shell 1 is destroyed, then the moving blades are extracted from the cluster for any machining and finishing and inspection operations.
  • stiffeners can be added to each radial arm 8 of the handling crown to stiffen the cluster and prevent it from collapsing under its own weight.
  • a handling ring and more generally of a handling accessory, totally independent of the bladed elements makes it possible to reduce the dimensioning of the handling ring compared to that formed by the supply system in a drop casting solution as previously described in the part relating to the prior art. This reduction in size can then lead to a reduction in the metal mass, in particular greater than 50%.
  • a handling accessory and in particular such a handling ring, can be made other than in metal, and in particular in ceramic, because it is only used for handling and no longer for supplying the bladed shell elements 4. As a result, the metal mass can even be reduced to zero if a material other than metal is used. This reduction in size and metal mass of the handling accessory can be done while maintaining sufficient mechanical properties.
  • casting the cluster at source can make it possible to preserve the metallurgical health of the parts formed. It is thus possible to reduce the risks of offset and core breakage because the attack speeds of the metal are very low, typically between 0.2 and 0.6 m/s. Furthermore, it is possible to reduce the metallurgical defects such as those of inclusion, oxidation, recrystallized grains, parasites, among others, as described above in connection with the state of the prior art.
  • the invention makes it possible to obtain ventilation of the cluster and an increase in its rigidity with better resistance to molding and finishing.
  • the principle in accordance with the invention aimed at isolating the handling ring from the bladed elements allows a reduction in the stresses and plastic deformations during solidification and cooling.
  • the invention in fact seeks to limit the thermomechanical stresses due to thermal gradients in the direction of directed solidification.
  • the risks of recrystallized grains and cold cracks are reduced with the solution of the invention.
  • the mold cools heterogeneously, with the bottom cooling first, causing cold metal to pull hot metal.
  • By controlling the temperature at the bottom of the mould it is possible to control the temperature gradient along the direction of solidification. A balance of the metal masses of the upper part with respect to the lower part is established, and the stresses on all the manufactured parts are reduced and better distributed.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
  • Supercharger (AREA)
EP17832291.3A 2016-12-26 2017-12-22 Modèle en forme de grappe et carapace pour obtention d'un accessoire de manutention indépendant de pièces formées et procédé associé Active EP3544754B1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
FR1663392A FR3061051B1 (fr) 2016-12-26 2016-12-26 Modele en forme de grappe et carapace pour obtention d'un accessoire de manutention independant de pieces formees et procede associe
PCT/FR2017/053815 WO2018122516A1 (fr) 2016-12-26 2017-12-22 Modèle en forme de grappe et carapace pour obtention d'un accessoire de manutention indépendant de pièces formées et procédé associé

Publications (2)

Publication Number Publication Date
EP3544754A1 EP3544754A1 (fr) 2019-10-02
EP3544754B1 true EP3544754B1 (fr) 2022-08-10

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EP17832291.3A Active EP3544754B1 (fr) 2016-12-26 2017-12-22 Modèle en forme de grappe et carapace pour obtention d'un accessoire de manutention indépendant de pièces formées et procédé associé

Country Status (8)

Country Link
US (1) US10875084B2 (ru)
EP (1) EP3544754B1 (ru)
JP (1) JP6965353B2 (ru)
CN (1) CN110114168B (ru)
CA (1) CA3048294A1 (ru)
FR (1) FR3061051B1 (ru)
RU (1) RU2757779C2 (ru)
WO (1) WO2018122516A1 (ru)

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CN109465399B (zh) * 2018-12-26 2023-11-21 广东富华铸锻有限公司 一种含有减速器壳砂芯结构的浇注系统
CN111136220A (zh) * 2019-12-16 2020-05-12 航天海鹰(哈尔滨)钛业有限公司 一种高温合金浇注用浇口杯成型工艺
CN111421111B (zh) * 2020-05-15 2021-11-30 贵州安吉航空精密铸造有限责任公司 一种用于熔模铸造工艺的浇道装置及其制备方法
CN114515818B (zh) * 2020-11-18 2024-04-26 中国航发商用航空发动机有限责任公司 一种航空发动机燃烧室涡流器的制造方法及模具
CN114905006A (zh) * 2021-02-07 2022-08-16 中国航发商用航空发动机有限责任公司 一种铸棒的制备方法及其制备系统
CN113042713B (zh) * 2021-02-26 2023-05-12 贵阳航发精密铸造有限公司 一种大尺寸或多联单晶导向叶片的引晶结构及制造装置
WO2023028535A1 (en) * 2021-08-24 2023-03-02 Chromalloy Gas Turbine Llc Systems and methods of bonding wax components for lost wax casting
CN113600747A (zh) * 2021-08-24 2021-11-05 中国航发沈阳黎明航空发动机有限责任公司 一种环块类结构件的多层单晶蜡模模组制造方法
CN114210926B (zh) * 2021-12-15 2023-09-22 中国航发动力股份有限公司 一种涡轮叶片熔模铸造型壳及其铸造工艺
FR3130659A1 (fr) * 2021-12-16 2023-06-23 Safran Aircraft Engines Moule de fonderie, sa fabrication et son utilisation
CN115055645B (zh) * 2022-06-07 2023-10-17 中国航发航空科技股份有限公司 导向器叶片毛坯的浇注系统
FR3139741A1 (fr) 2022-09-16 2024-03-22 Safran Aircraft Engines Grappe de modeles realises en cire et moule pour la fabrication par moulage a cire perdue d’une pluralite d’elements de turbomachine
CN115921790B (zh) * 2022-12-26 2024-01-23 中国航发北京航空材料研究院 一种细长薄壁叶片浇注系统设计方法

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SU1507512A1 (ru) * 1987-11-30 1989-09-15 Предприятие П/Я М-5906 Литникова система дл отливки рабочего колеса турбомашины
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FR2985924B1 (fr) 2012-01-24 2014-02-14 Snecma Carapace pour la fabrication par moulage a cire perdue d'elements aubages de turbomachine d'aeronef, comprenant des ecrans formant accumulateurs de chaleur
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FR3026973B1 (fr) 2014-10-14 2016-12-23 Snecma Modele en forme de grappe et carapace ameliores pour la fabrication par moulage a cire perdue d'elements aubages de turbomachine d'aeronef
RU2597491C2 (ru) * 2015-01-19 2016-09-10 Акционерное общество "Научно-производственный центр газотурбостроения "Салют" (АО "НПЦ газотурбостроения "Салют") Устройство и керамическая оболочка для получения отливок с монокристаллической и направленной структурой
CN105290333B (zh) * 2015-12-02 2017-10-27 株洲中航动力精密铸造有限公司 底注式浇注系统

Also Published As

Publication number Publication date
CN110114168A (zh) 2019-08-09
EP3544754A1 (fr) 2019-10-02
CA3048294A1 (fr) 2018-07-05
JP6965353B2 (ja) 2021-11-10
FR3061051A1 (fr) 2018-06-29
RU2757779C2 (ru) 2021-10-21
RU2019123466A3 (ru) 2021-07-22
US20200101526A1 (en) 2020-04-02
RU2019123466A (ru) 2021-01-26
CN110114168B (zh) 2020-11-06
BR112019013085A2 (pt) 2019-12-17
FR3061051B1 (fr) 2019-05-31
WO2018122516A1 (fr) 2018-07-05
US10875084B2 (en) 2020-12-29
JP2020504012A (ja) 2020-02-06

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