EP4370261B1 - Verbesserter giesskern zur herstellung eines hohlen aeronautischen metallteils - Google Patents

Verbesserter giesskern zur herstellung eines hohlen aeronautischen metallteils

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Publication number
EP4370261B1
EP4370261B1 EP22754470.7A EP22754470A EP4370261B1 EP 4370261 B1 EP4370261 B1 EP 4370261B1 EP 22754470 A EP22754470 A EP 22754470A EP 4370261 B1 EP4370261 B1 EP 4370261B1
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EP
European Patent Office
Prior art keywords
phase
core
casting
composite material
alc
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Active
Application number
EP22754470.7A
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English (en)
French (fr)
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EP4370261A1 (de
Inventor
Pierre Jean SALLOT
Mirna Bechelany
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Safran SA
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Safran SA
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Publication of EP4370261A1 publication Critical patent/EP4370261A1/de
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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
    • 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
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/10—Cores; Manufacture or installation of cores
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/18—Finishing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D29/00—Removing castings from moulds, not restricted to casting processes covered by a single main group; Removing cores; Handling ingots
    • B22D29/001—Removing cores
    • B22D29/002—Removing cores by leaching, washing or dissolving
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D29/00—Removing castings from moulds, not restricted to casting processes covered by a single main group; Removing cores; Handling ingots
    • B22D29/001—Removing cores
    • B22D29/003—Removing cores using heat

Definitions

  • the invention relates to the manufacture of hollow metal aeronautical parts, in particular aeronautical turbomachine blades, by lost wax casting methods. More specifically, the invention relates to the foundry core used in the manufacture of hollow aeronautical parts, to a method of manufacturing such a foundry core, and to a method of manufacturing such an aeronautical part.
  • Metal aircraft parts particularly nickel-based high-pressure turbine blades, typically have internal cooling channels, making these parts hollow.
  • TET temperature turbine inlet gas
  • Cooling circuits in particular play a major role in achieving these objectives.
  • the complexity of these circuits tends to increase, integrating very thin and long sections.
  • these circuits can be difficult to manufacture. Indeed, given the fragility of the ceramic composition used and the need to use demouldable shapes, the development of such circuits by ceramic injection into a mould, which represents the process generally used for the manufacture of foundry cores, can be laborious and expensive, notably presenting a high reject rate.
  • the first phase is of the “MAX phase” type, a crystal structure of generic formula M n+1 AX n , combining characteristics of both metals and ceramics, and in particular having good thermal and electrical conductivity, good machinability, as well as damage tolerance and resistance to oxidation at high temperature.
  • the expression “for the manufacture of hollow metal aeronautical parts” means that the core is adapted and suitable for the manufacture of such metal parts.
  • a core having the same composition may also be suitable for the manufacture of ceramic matrix composite (CMC) parts, in particular.
  • the use of aluminum on site A makes it possible to ensure either the formation of a protective alumina layer by oxidation of the core, or compatibility with aluminoforming coatings possibly deposited on the core.
  • the use of carbon on site X is advantageous in that the carbide-type phases thus formed have a melting temperature greater than 1500°C, and therefore greater than the melting temperature of the metal used during the casting of the molten metal into the shell mold. Carbon also makes it possible to form phases that are chemically compatible with Al 4 C 3 .
  • titanium and/or niobium and/or molybdenum, used on the M site make it possible, in coordination with the use of carbon, to obtain phases with melting temperatures higher than that of the metal used during casting, and also having good mechanical properties up to at least 1500°C.
  • this first phase with a second phase of formula Al 4 C 3 is particularly advantageous.
  • aluminum carbide (Al 4 C 3 ) is an inorganic compound, whose melting temperature is very high (2200°C), and which can easily hydrolyze at room temperature, in the presence of a water-rich atmosphere.
  • the composite material used for the foundry core of the present disclosure integrates this second phase of aluminum carbide into the grain boundaries of the first phase. This makes the composite material particularly reactive to atmospheres containing water.
  • the degradation of the aluminum carbide is accompanied by a variation in volume and a release of gas, capable of fragmenting the grain boundary and propagating cracks in the first initial phase. It is thus possible to propagate the hydrolysis phenomenon over relatively large distances, and thus facilitate the fragmentation and detachment of the core.
  • the composite material forming the core can be initially dense and massive, and be reduced to powder by hydrolysis.
  • the chemical gradient between the aluminum carbide and the first phase containing aluminum and carbon is very limited, which limits the interdiffusion between the different chemical elements during the core shaping and casting stages.
  • a fragmented material composed of grains of the first phase and hydrated aluminum, can be recovered. After drying, this material can be "recharged” with Al 4 C 3 and reused to manufacture new foundry cores.
  • the composite material of the foundry core according to the present disclosure thus combines the aforementioned advantages linked to the refractory compounds of the first phase, with the use of a second phase of formula Al 4 C 3 , allowing the production of hollow structures of complex shapes, while allowing easy and rapid decoupling of fine cores, without having to resort to chemical solutions potentially harmful to the part subsequently manufactured and to the environment, and which can be recycled.
  • the first phase is of one of the formulas Nb 4 AlC 3 , Nb 2 AlC, Mo 2 TiAlC 2 or Ti 2 AlC.
  • the Ti 2 AlC phase is aluminoforming and therefore does not require the addition of a coating to allow the formation of this protective layer. Its coefficient of thermal expansion is of the order of 7-9x10 -6 K -1 , which is close to alumina, and prevents flaking of the oxide formed at high temperature.
  • the Nb 4 AlC 3 , Nb 2 AlC, Mo 2 TiAlC 2 phases are not aluminoforming. It is preferable to add a coating allowing the formation of this protective layer. However, their coefficient of thermal expansion is also of the order of 7-9x10 -6 K -1 , close to alumina, and therefore allows the direct deposition of an alumina layer or an aluminoforming coating.
  • the composite material comprises between 1 and 50% of second phase by volume of the composite material, preferably between 1 and 20%. These values make it possible to ensure the fragmentation of the composite material by hydrolysis, while leaving a sufficient volume of first phase in the composite material, making it possible to retain the technical advantages linked to this first phase. In addition, this fraction of Al 4 C 3 phase makes it possible to ensure the chemical stability of the material at high temperature, while making it possible to induce a hydrolysis phenomenon facilitating debonding.
  • an outer surface of the foundry core is covered with a layer of alumina.
  • Degradation of the core by hydrolysis of the aluminum carbide in an atmosphere containing water, should only occur during core shakeout.
  • the presence of a dense, adherent alumina layer on the surface of the core protects the composite material from degradation during the other stages of manufacturing a casting prior to core shakeout, particularly during the wax removal stage.
  • the alumina layer has a thickness of between 1 and 50 ⁇ m. This thickness provides protection for the core during the manufacture of a casting. More specifically, the alumina layer thus formed is thin enough not to impact core removal by knockout, but chemically isolates the core from the outside.
  • the mixture of powders used to obtain the composite material may comprise the mixture of pure powders of carbon, aluminum, titanium and/or titanium carbide, and/or niobium, and/or niobium carbide and/or molybdenum and/or aluminum carbide Al 4 C 3 .
  • the composite material constituting the foundry core is obtained by reacting the different powders of the constituent elements of this material at high temperature. This process has the advantage of involving, in the production of the composite material, the Al 4 C 3 phase, making it possible to provide the necessary elements AI and C, thus providing the aforementioned advantages.
  • the shaping step may comprise the injection of a binder onto a powder (called “binder jetting” in English), the injection of a mixture of metal powder and a thermoplastic polymer (or MIM process for “Metal Injection Molding” in English) or any other suitable known 3D printing process, preferably followed by conventional debinding and/or sintering, or unconventional debinding and/or sintering such as “flash sintering” (or SPS sintering for “Spark Plasma Sintering” in English), for example.
  • the mixing step comprises mixing pure powders constituting the first phase so as to obtain the first phase in powder form, then mixing said first phase in powder form with an Al 4 C 3 powder so as to obtain the second phase.
  • pure powders of carbon, aluminum, titanium and/or titanium carbide, and/or niobium, and/or niobium carbide, and/or molybdenum, and/or aluminum carbide are mixed first, so as to obtain the first phase in a first step, then the first phase obtained is mixed with an aluminum carbide powder in a second step, so as to obtain the second phase. This allows for improved control of the proportions of each phase.
  • the mixing step comprises mixing pure powders constituting the first phase with excess Al 4 C 3 powder so as to form the composite material in one operation.
  • the mixing of the powders is not carried out in two stages (manufacturing of the first phase in the first stage, then mixing with an aluminum carbide powder), but the aforementioned pure powders are mixed in the same operation with an excess Al 4 C 3 powder, i.e. in over-stoichiometry, thus allowing the formation of the composite material "in situ".
  • the fact of reacting the Al 4 C 3 powder in over-stoichiometry with respect to the first desired phase makes it possible to maintain a controlled volume fraction of this phase in the final material.
  • the first phase is of formula Ti 2 AlC, the method comprising, after the step of shaping the foundry core, a step of oxidizing the core allowing the formation of an alumina layer on a surface of the core.
  • the Ti 2 AlC formula phase is aluminoforming, and thus allows the formation of an alumina layer by simple oxidation of the core, without requiring the addition of a complex multi-layer coating allowing the formation of this protective layer.
  • this core degradation step must only be able to be activated after the casting has been carried out.
  • This oxidation step makes it possible to produce an adherent and dense alumina layer on the surface of the core capable of protecting the composite material from degradation, in particular during the dewaxing step. It should also be noted that since the subsequent metal casting step is carried out under vacuum, the latter does not pose any particular problem with these materials.
  • the first phase is of one of the formulas Nb 4 AlC 3 , Nb 2 AlC, Mo 2 TiAlC 2 , the method comprising, after the step of shaping the foundry core, a step of depositing an aluminoforming coating, then an oxidation step of the coating allowing the formation of a layer of alumina on a surface of the core.
  • these phases are not aluminoforming, and therefore require the addition of a coating to allow the formation of this protective layer.
  • these phases are compatible with aluminoforming coatings capable of forming an alumina layer by oxidation. It is thus possible to form a protective alumina layer in a simple manner, without requiring the addition of a complex multi-layer coating to form this protective layer.
  • the oxidation step is carried out by placing the core in an enclosure under air between 1000°C and 1400°C.
  • the present disclosure also relates to a method of manufacturing by lost wax casting a hollow metal aeronautical part, in particular a high-pressure turbine part, using a foundry core obtained by a method according to any one of the preceding embodiments, the method comprising, after steps of casting a molten metal around the foundry core and solidifying said metal, a step of detaching the foundry core by baking.
  • the assembly is placed in a device, for example an oven, preferably with controlled humidity.
  • a device for example an oven, preferably with controlled humidity.
  • the presence of the Al 4 C 3 phase between the grain boundaries allows, in air laden with water, the disintegration of the foundry core. This thus facilitates shakeout, and in particular improves shakeout of very fine channels, while avoiding the use of chemical solutions, such as acids, which are potentially harmful to the manufactured part.
  • the method comprises, before the knockout step, a step in which an opening is made in the part.
  • the casting devices are eliminated and an opening is made in the part without the alumina layer. This makes it possible to further facilitate the detachment of the core, the composite material thus degraded being able to be evacuated via this opening.
  • the method comprises, after the decoking step, a recovery step, in which the decoking material by baking is recovered so that it can be reused for the manufacture of another foundry core starting from the mixing stage.
  • a fragmented material composed of grains from the first phase and hydrated aluminum can be recovered. After drying, this material can be "recharged” with Al 4 C 3 during the mixing step and thus be reused to manufacture new cores. It is thus possible to recycle the de-molded foundry core, thus providing at least a partial response to the aforementioned environmental issues.
  • the present disclosure also relates to a method for manufacturing a hollow aeronautical part made of ceramic matrix composite using a core obtained by a method according to any one of the preceding embodiments, the method comprising, after steps of inserting the core into a fiber preform, impregnating a ceramic matrix into the fiber preform and solidifying the matrix, a step of demoulding the core by baking.
  • the foundry core obtained by a method according to the present disclosure is more simply called a “core” when it is used for the manufacture of ceramic matrix composite (CMC) parts.
  • FIG 1 represents a perspective view of a hollow blade 10 of a high pressure turbine
  • the figure 2 represents a sectional view of said blade 10, showing the different cooling circuits 12 within this blade 10.
  • Such a blade is obtained, according to the present disclosure, by a lost wax casting process.
  • the cooling circuits 12 are obtained by using, during the manufacturing process, a foundry core 1, manufactured during a preliminary step of the process, and the shape of which corresponds to the shape of the cooling circuits 12 intended to be formed.
  • Such a foundry core 1, in accordance with the present disclosure, is shown in perspective on the figure 3 . Certain portions 2 of this core 1, making it possible to obtain the different cooling channels 12, are complex or thin. Nevertheless, the foundry core 1 according to the present disclosure comprises a composite material making it easier to remove this core 1, during the shake-out step described later.
  • the composite material comprises two phases: a first phase called the “MAX phase”, and a second phase with the formula Al 4 C 3 , in other words aluminium carbide.
  • the element used in group A is aluminum (Al) in order to ensure either the formation of an alumina layer when aluminoforming phases are used, or compatibility with subsequently deposited aluminoforming coatings.
  • the element used at site X is carbon (C). Indeed, phases containing nitrogen (N) often have lower melting temperatures than their carbon-containing counterparts and chemical compatibility with the Al 4 C 3 phase is not ensured.
  • the element used at site M is determined such that the resulting material has a melting point above 1500°C.
  • Chromium (Cr)-based MAX phases such as Cr 2 AlC for example, are not suitable for the present application because they begin to decompose around 1500°C.
  • zirconium (Zr)-based MAX phases have too low a melting temperature, notably below 1500°C.
  • the first phase used may be of formula Nb 4 AlC 3 , Nb 2 AlC, Mo 2 TiAlC 2 or Ti 2 AlC.
  • the second phase of formula Al 4 C 3 is a known carbide with a very high melting temperature (2200°C). It is also aluminoformable at high temperatures.
  • the particularly advantageous property in the context of the invention is the ease with which this phase hydrolyzes at room temperature in the presence of a water-rich atmosphere.
  • the decomposition of this phase follows the following reaction: Al 4 C 3 + 12 H 2 O ⁇ 4 Al(OH) 3 + 3 CH 4
  • This reaction can be catalyzed by optimizing the humidity level but also the temperature.
  • the foundry core 1 comprising this composite material can be easily removed by being degraded by hydrolysis, at the end of the blade manufacturing process.
  • the method of manufacturing blades according to the present disclosure is a lost wax casting method.
  • the different stages of this method, according to a first embodiment, are presented on the figure 4 .
  • the first step S100 of this method consists of manufacturing the casting core 1 described above, intended to be subsequently used in the manufacture of hollow turbomachine blades using the lost wax casting technique.
  • the casting core 1 thus manufactured in step S100 is placed in a wax mold, being held in a predetermined position, so as to inject wax around the core to form the wax model having the shape of the final part (step S200).
  • the wax model is then repeatedly dipped into a slip in order to form a ceramic mold (step S300).
  • step S400 After removal of the wax (step S400), obtained by placing the assembly in an autoclave furnace, for example, the molten metal, for example nickel-based alloys, is poured into the ceramic mold and around the ceramic core, the latter being again held in a fixed position inside the ceramic mold, and the metal is then solidified by controlled solidification (step S500). Finally, the ceramic mold and the foundry core 1 are removed by demoulding, in order to obtain the final part (step S600).
  • step S400 After removal of the wax (step S400), obtained by placing the assembly in an autoclave furnace, for example, the molten metal, for example nickel-based alloys, is poured into the ceramic mold and around the ceramic core, the latter being again held in a fixed position inside the ceramic mold, and the metal is then solidified by controlled solidification (step S500). Finally, the ceramic mold and the foundry core 1 are removed by demoulding, in order to obtain the final part (step S600).
  • the molten metal for example nickel-based alloys
  • step S100 of manufacturing the foundry core 1 is divided into several steps. Firstly, metal powders are mixed together, so as to obtain a composite powder comprising the first and second phases (step S110).
  • metal powders are mixed together, so as to obtain a composite powder comprising the first and second phases (step S110).
  • pure powders of aluminum (Al), carbon (C), niobium (Nb), and/or niobium carbide (NbC) and/or molybdenum (Mo) and/or titanium (Ti), and/or titanium carbide (TiC) are mixed with an excess Al 4 C 3 aluminum carbide powder, so as to form in situ a composite material comprising the first phase and the second phase, such that the second phase represents between 1 and 50%, preferably between 1 and 20% of the total volume of the composite material.
  • the foundry core 1 is shaped (step S120), so that the latter takes the desired shape.
  • This step can be carried out by various known methods such as the injection of a binder onto a powder (called “binder jetting” in English), the injection of a mixture of metal powder and a thermoplastic polymer (or MIM process for "Metal Injection Molding” in English) or any other suitable known 3D printing process, preferably followed by conventional debinding and/or sintering, or by unconventional debinding and/or sintering such as for example “flash sintering” (or SPS sintering for "Spark Plasma Sintering” in English), or any other suitable known process, or a combination of these different processes.
  • step S140 a step of forming an alumina layer, making it possible to form an alumina layer with a thickness of between 1 and 50 ⁇ m is carried out (step S140).
  • This step is carried out by oxidation of the foundry core 1 by bringing the latter to a temperature of between 1000 and 1400°C.
  • a preliminary step to this oxidation step may be necessary.
  • the phases of formula Nb 4 AlC 3 , Nb 2 AlC, Mo 2 TiAlC 2 are not aluminoforming, so that bringing a core 1 comprising a composite material having one of these first phases to a temperature of between 1000 and 1400°C will not allow the formation of an alumina layer. Therefore, in this case, step S120 of shaping the core is followed by a step of depositing an aluminoforming coating (step S130).
  • a layer of molybdenum (Mo) can be deposited directly onto the core by thermal spraying. Silicon (Si) and aluminum are then deposited by pack-cementation at 1100°C. A treatment of a few hours in air at 1200°C allows the formation of an alumina layer on the surface. Direct deposition of aluminum by cementation or sol-gel, followed by oxidation in air at 1100°C is also possible.
  • This aluminoforming coating can also be deposited by known techniques such as chemical vapor deposition (CVD), physical vapor deposition (PVD), or dip coating, for example.
  • step S120 of shaping the core 1 can be followed immediately by step S140 of forming the alumina layer by oxidation, without requiring a prior step of depositing a coating.
  • the foundry core 1 thus obtained, comprising an alumina layer on its external surface, can then be used in the process for manufacturing parts by lost wax casting described above, in particular in step S200 of injecting the wax around the core 1 to form the wax model.
  • the internal structure of the core 1 will not be affected by the step of removing the wax (step S400), due to the presence of the alumina layer on its external surface.
  • step S600 comprising the shake-out of the foundry core 1
  • a hygrometry-controlled oven relative humidity RH >50%) or preferably in a steam autoclave, at temperatures between 100 and 180°C, and pressures between 6 and 12 bars.
  • the application of pressure makes it possible to accelerate the shake-out kinetics while facilitating access of the vapors to the thin sections.
  • This step is preferably preceded by a step of forming an opening in the part, making it possible to facilitate the evacuation of the core 1 degraded by hydrolysis in the aforementioned oven.
  • the alumina layer can be evacuated at the same time as the degrading composite, or can also remain adherent to the nickel-based superalloy, providing protection against internal oxidation of the cooling channels.
  • step S700 the detachment step S600 can be followed by a recovery step (step S700), or recycling, in which the composite material detached by baking, then in powder form, is recovered so as to be reused for the manufacture of another foundry core 1, starting again from the mixing step S110. More precisely, once the core has been degraded, a fragmented material composed of grains from the first phase and hydrated aluminum is recovered. After drying, this material can be "recharged” with Al 4 C 3 and reused to manufacture new foundry cores 1.
  • step S110 of mixing the powders differs from the method according to the first embodiment in that step S110 of mixing the powders is broken down into two sub-steps.
  • step S110 of mixing the powders in the context of the second embodiment comprises, firstly, the mixing of pure powders constituting the first phase making it possible to obtain the first phase (step S111), then the mixing of the first phase thus obtained with an Al 4 C 3 powder making it possible to obtain the composite material ex situ (step S112).
  • a first phase of formula Nb 4 AlC 3 can be obtained by mixing pure powders of niobium, aluminum and niobium carbide (Nb: Al: NbC) in the molar proportions 1.2: 1.1: 2.8 respectively.
  • the niobium grains have a diameter of less than 44 ⁇ m, a purity of 99.8%, and a density of 8.57 g/cm 3 .
  • the aluminum grains have a diameter of less than 44 ⁇ m, a purity of 99.5%, and a density of 2.70 g/cm 3
  • the niobium carbide grains have a diameter of less than 10 ⁇ m, a purity of 99%, and a density of 7.82 g/cm 3 .
  • a first phase of formula Ti 3 AlC 2 can be obtained by mixing pure powders of titanium, aluminum and titanium carbide (Ti: Al: TiC) in the molar proportions 1: 1.05: 1.9 respectively.
  • the titanium grains have a diameter less than 45 ⁇ m, a purity of 99.5%.
  • the aluminum grains have a diameter between 45 and 150 ⁇ m, a purity of 99.5% and the titanium carbide grains have a diameter of 2 ⁇ m, a purity of 99.5%, and a density of 7.82 g/cm3.
  • These different powders can be mixed in a ball mixer, then subjected to reactive sintering up to 1450°C. The porous mass thus obtained is ground to be reduced to powder.
  • the pure powders can also be mixed with an Al 4 C 3 powder.
  • the Al 4 C 3 powder contributes to the formation of the first phase, but is not in sufficient quantity to form the composite material in situ, so that the second step S112 is necessary, and makes it possible to add a necessary quantity of Al 4 C 3 powder, making it possible to obtain the proportions of Al 4 C 3 mentioned above in the composite material.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)

Claims (14)

  1. Gießkern (1) zur Herstellung eines hohlen aeronautischen Metallteils, insbesondere eines Hochdruckturbinenteils im Wachsausschmelzverfahren, umfassend einen Verbundwerkstoff, der einerseits eine erste Phase der Formel Mn+iAlCn umfasst, wobei n = 1 bis 3 und M ein Übergangsmetall ist, das aus der Gruppe ausgewählt ist, die aus Titan und/oder Niob und/oder Molybdän besteht, und andererseits eine zweite Phase der Formel Al4C3.
  2. Gießkern (1) nach Anspruch 1, wobei die erste Phase eine der Formeln Nb4AlC3, Nb2AlC, Mo2TiAlC2 oder Ti2AlC ist.
  3. Gießkern (1) nach Anspruch 1 oder 2, wobei der Verbundwerkstoff zwischen 1 und 50 Vol.-% der zweiten Phase des Verbundwerkstoffs, vorzugsweise zwischen 1 und 20 Vol.-%, umfasst.
  4. Gießkern (1) nach einem der Ansprüche 1 bis 3, wobei eine Außenfläche des Gießkerns (1) mit einer Aluminiumoxidschicht bedeckt ist.
  5. Gießkern (1) nach Anspruch 4, wobei die Aluminiumoxidschicht eine Dicke zwischen 1 und 50 µm aufweist.
  6. Verfahren zur Herstellung eines Gießkerns (1) zur Herstellung eines hohlen aeronautischen Metallteils, insbesondere eines Hochdruckturbinenteils im Wachsausschmelzverfahren, der Gießkern (1) umfassend einen Verbundwerkstoff, der einerseits eine erste Phase der Formel Mn+iAlCn, wobei n = 1 bis 3 und M ein Übergangsmetall ist, das aus der Gruppe ausgewählt ist, die aus Titan und/oder Niob und/oder Molybdän besteht, und andererseits eine zweite Phase der Formel Al4C3 umfasst, wobei der Gießkern (1) durch ein pulvermetallurgisches Verfahren erhalten wird, das einen Mischschritt, in dem Pulver, die es ermöglichen, den Verbundwerkstoff zu erhalten, gemischt werden, und einen Formgebungsschritt umfasst.
  7. Verfahren nach Anspruch 6, wobei der Mischschritt das Mischen der reinen Pulver, aus denen die erste Phase besteht, derart umfasst, dass die erste Phase in Pulverform erhalten wird, und anschließend das Mischen der ersten Phase in Pulverform mit einem Al4C3-Pulver, so dass die zweite Phase erhalten wird.
  8. Verfahren nach Anspruch 6, wobei der Mischschritt das Mischen der reinen Pulver, aus denen die erste Phase besteht, mit einem überschüssigen Al4C3-Pulver umfasst, um den Verbundwerkstoff in einem Arbeitsgang zu bilden.
  9. Verfahren nach einem der Ansprüche 6 bis 8, wobei die erste Phase die Formel Ti2AlC hat, wobei das Verfahren nach dem Formgebungsschritt des Gießkerns einen Schritt des Oxidierens des Kerns umfasst, der die Bildung einer Aluminiumoxidschicht auf einer Oberfläche des Kerns ermöglicht.
  10. Verfahren nach einem der Ansprüche 6 bis 8, wobei die erste Phase eine der Formeln Nb4AlC3, Nb2AlC, Mo2TiAlC2 ist, wobei das Verfahren nach dem Formgebungsschritt des Gießkerns einen Schritt des Aufbringens einer aluminiumoxidbildenden Beschichtung und anschließend einen Oxidationsschritt der Beschichtung umfasst, der die Bildung einer Aluminiumoxidschicht auf einer Oberfläche des Kerns erlaubt.
  11. Verfahren zur Herstellung eines hohlen aeronautischen Metallteils, insbesondere eines Hochdruckturbinenteils im Wachsausschmelzverfahren, unter Verwendung eines Gießkerns (1), der nach einem Verfahren nach einem der Ansprüche 6 bis 10 hergestellt wird, wobei das Verfahren nach den Schritten des Gießens einer Metallschmelze um den Gießkern und des Erstarrens des Metalls einen Schritt des Entformens des Gießkerns durch Ausglühen umfasst.
  12. Verfahren nach Anspruch 11, das vor dem Entformungsschritt einen Schritt umfasst, in dem eine Öffnung in dem Teil hergestellt wird.
  13. Verfahren nach Anspruch 11 oder 12, das nach dem Entformungsschritt einen Rückgewinnungsschritt umfasst, in dem das durch Ausglühen entformte Material derart zurückgewonnen wird, dass es zur Herstellung eines anderen Gießkerns wiederverwendet werden kann, wobei wieder mit dem Mischschritt begonnen wird.
  14. Verfahren zur Herstellung eines hohlen aeronautischen Teils aus einem Verbundwerkstoff mit Keramikmatrix unter Verwendung eines Kerns (1), der durch ein Verfahren nach einem der Ansprüche 6 bis 10 erhalten wurde, wobei das Verfahren nach den Schritten des Einlegens des Kerns (1) in eine faserige Vorform, des Imprägnierens einer Keramikmatrix in die faserige Vorform und des Verfestigens der Matrix einen Schritt des Entformens des Kerns (1) durch Ausglühen umfasst.
EP22754470.7A 2021-07-16 2022-07-12 Verbesserter giesskern zur herstellung eines hohlen aeronautischen metallteils Active EP4370261B1 (de)

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FR2107726A FR3125237B1 (fr) 2021-07-16 2021-07-16 Noyau de fonderie amélioré pour la fabrication de pièce aéronautique métallique creuse
PCT/FR2022/051406 WO2023285766A1 (fr) 2021-07-16 2022-07-12 Noyau de fonderie amélioré pour la fabrication de pièce aéronautique métallique creuse

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US4164424A (en) * 1977-10-06 1979-08-14 General Electric Company Alumina core having a high degree of porosity and crushability characteristics
US4187266A (en) * 1977-10-06 1980-02-05 General Electric Company Process for making a ceramic article having a dense integral outer barrier layer and a high degree of porosity and crushability characteristics
US4184885A (en) * 1979-01-25 1980-01-22 General Electric Company Alumina core having a high degree of porosity and crushability characteristics
US4221748A (en) * 1979-01-25 1980-09-09 General Electric Company Method for making porous, crushable core having a porous integral outer barrier layer having a density gradient therein
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FR3125237B1 (fr) 2023-07-14
FR3125237A1 (fr) 2023-01-20
WO2023285766A1 (fr) 2023-01-19
EP4370261A1 (de) 2024-05-22
US12121955B1 (en) 2024-10-22
CN117642239A (zh) 2024-03-01

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