JP2017501875A - 炭化ケイ素を含有する鋳型及びフェースコート組成物並びにチタン及びチタンアルミナイド合金の鋳造方法 - Google Patents
炭化ケイ素を含有する鋳型及びフェースコート組成物並びにチタン及びチタンアルミナイド合金の鋳造方法 Download PDFInfo
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Abstract
Description
本開示の態様は、チタン及びチタン合金の改良部品を提供することのできるインベストメント鋳型用の組成物を提供する。本開示の一態様では、一アルミン酸カルシウムは、アルミン酸カルシウムセメントの形態で提供されることができる。アルミン酸カルシウムセメントは、「セメント」又は「バインダー」と呼ばれることがある。
本開示は、とりわけ、チタン及びチタン合金の改良部品を提供することのできるインベストメント鋳型用の組成物に関する。鋳型は、鋳型本体と鋳型キャビティとの間に炭化ケイ素を含む連続内在性フェースコートを含む。外形寸法が約50μm未満の炭化ケイ素粉末の大きさが、鋳型製造プロセスで用いられる。本願の発明者らは、この大きさの炭化ケイ素粉末を使用することが、鋳型製造中に粒子のフェースコートへの偏析を促進することを見出した。従って、炭化ケイ素が鋳型のフェースコートに存在することは、好ましい性質をもたらす。鋳型本体も炭化ケイ素を含有してよい。
ある種の実施形態では、鋳型は、鋳型本体と鋳型キャビティとの間に連続する炭化ケイ素含有内在性フェースコートを含む。鋳型は、鋳型製造時に向上した鋳型強度を提供する相を含むように設計され、連続するフェースコートは、鋳造中に熱伝導率の増加及び反応に対する抵抗性の増加を提供するように設計される。鋳型は、高圧で鋳造することができ、ネットシェイプ鋳造方法に望ましい。性質の改善された鋳物をもたらす鋳型組成物、フェースコート組成物、並びにフェースコート及び鋳型本体に好ましい構成相が特定された。
インベストメント鋳型は、セラミック部品のインベストメント混合物を配合し、混合物を消失性模型を含む容器に注入することにより形成される。模型上で形成されたインベストメント鋳型を完全に硬化させて、いわゆる「生型」を形成する。炭化ケイ素を含有する内在性フェースコート及びインベストメント鋳型は、模型上で形成され、それらを完全に硬化させてこの生型を形成する。一般的に、生型の硬化は1時間〜48時間実施される。その後、消失性模型は、溶融、溶解、点火、又はその他の公知の模型除去技術によって生型から選択的に除去される。ワックス模型除去の典型的な方法としては、オーブン脱蝋(150℃未満)、炉脱蝋(150℃超)、蒸気オートクレーブ脱蝋及びマイクロ波脱蝋が挙げられる。
Claims (25)
- チタン含有物品の鋳造用の鋳型を形成する方法であって、
アルミン酸カルシウム及び炭化ケイ素を液体と混合してスラリーを生成する工程であって、スラリー中の固形分がスラリー重量の約60〜約80重量%であり、スラリーの粘度が約30〜約1500cPである工程と、
スラリーを、消失性模型を有する鋳型キャビティ内に注入する工程と、
スラリーを鋳型キャビティ内で硬化させて、チタン含有物品の鋳造用の鋳型を形成する工程と
を含む、方法。 - 炭化ケイ素粒子が約10〜約50μmの外形寸法である、請求項1に記載の方法。
- アルミン酸カルシウムがスラリー重量の20重量%超をなす、請求項1に記載の方法。
- アルミン酸カルシウムの粒径が、外形寸法で約50μm未満である、請求項1に記載の方法。
- スラリーが酸化物粒子をさらに含む、請求項1に記載の方法。
- 酸化物粒子が中空である、請求項5に記載の方法。
- 酸化物粒子が、酸化アルミニウム粒子、酸化マグネシウム粒子、酸化カルシウム粒子、酸化ジルコニウム粒子、酸化チタン粒子、酸化ケイ素粒子及びそれらの組成物からなる群から選択される、請求項5に記載の方法。
- 酸化物粒子が酸化アルミニウム粒子である、請求項5に記載の方法。
- 酸化アルミニウム粒子が、スラリー重量の約30〜約68重量%をなす、請求項8に記載の方法。
- 酸化アルミニウム粒子が、約50〜約1500μmの外形寸法である、請求項8に記載の方法。
- スラリーを鋳型キャビティに注入する前に、大型中空酸化物粒子をスラリーに添加して、スラリー中の固形分がスラリー重量の約70%〜約95重量%となるように、最終アルミン酸カルシウム−液体セメント混合物を形成する、請求項1に記載の方法。
- スラリー重量の約10重量%超で約50重量%未満が酸化カルシウムとなるように添加された酸化カルシウムをさらに含む、請求項1に記載の方法。
- スラリー中の固形分が約60〜約78%である、請求項1に記載の方法。
- 2%未満のシリカをスラリーに添加することをさらに含む、請求項1に記載の方法。
- チタン及びチタン合金の鋳造方法であって、
アルミン酸カルシウム及び大型酸化アルミニウムを含むインベストメント鋳型組成物を得る工程であって、最終混合物中の固形分がスラリー重量の約70%〜約95重量%となるように、アルミン酸カルシウム及びアルミナを液体及び炭化ケイ素と混合して、最終アルミン酸カルシウム/液状混合物スラリーを生成させる工程と、
インベストメント鋳型組成物を、消失性模型を収容した容器に注入する工程と、
インベストメント鋳型組成物を硬化させる工程と、
消失性模型を鋳型から除去する工程と、
鋳型を焼成する工程と、
鋳型を鋳型鋳造温度に予熱する工程と、
溶融チタン又はチタン合金を、加熱した鋳型に注入する工程と、
溶融チタン又はチタン合金を凝固させる工程と、
凝固したチタン又はチタン合金鋳物を形成する工程と、
凝固したチタン又はチタン合金鋳物を鋳型から取り出す工程と
を含む、方法。 - 酸化アルミニウムの粒子が約50〜約1500μmの外形寸法である、請求項15に記載の方法。
- 炭化ケイ素粒子が約10〜約100μmの外形寸法である、請求項15に記載の方法。
- 炭化ケイ素が15重量%〜45重量%存在し、炭化ケイ素なしで実施した鋳造に比べて、鋳造時に25%以上増大した熱伝導率をもたらす、請求項15に記載の方法。
- アルミン酸カルシウム、炭化ケイ素及び酸化アルミニウムを含むインベストメント鋳型を用意する工程と、
溶融チタン又はチタン合金を鋳型に注入する工程と、
溶融チタン又はチタン合金を凝固させる工程と、
凝固したチタン又はチタン合金鋳物を形成する工程と、
凝固したチタン又はチタン合金鋳物を鋳型から取り出して、タービンブレードを製造する工程と
を含む方法で製造されたタービンブレードであって、タービンブレードが、その表面積の少なくとも一部分で20未満の平均粗さRaを有する、タービンブレード。 - 炭化ケイ素粒子が約10〜約100μmの外形寸法である、請求項19に記載の方法。
- 炭化ケイ素が15重量%〜45重量%存在し、炭化ケイ素なしで実施した鋳造に比べて、鋳造時に25%以上増大した熱伝導率をもたらす、請求項19に記載の方法。
- タービン部品の製造方法であって、
アルミン酸カルシウム、二アルミン酸カルシウム、炭化ケイ素、マイエナイト及び水を含む混合物から鋳型を製造する工程であって、炭化ケイ素が約15%〜約45重量%で存在する工程と、
鋳型を焼成する工程と、
溶融チタン又はチタン合金を鋳型に注入する工程と、
溶融チタン又はチタン合金を凝固させて、凝固した鋳物を形成する工程と、
鋳物を鋳型から取り出す工程と
を含む方法。 - 約50μmよりも大きい中空酸化アルミニウム粒子をさらに含む、請求項22に記載の方法。
- 炭化ケイ素粒子が約10〜約100μmの外形寸法である、請求項22に記載の方法。
- 炭化ケイ素が15重量%〜45重量%存在し、炭化ケイ素なしで実施した鋳造に比べて、鋳造時に25%以上増大した熱伝導率をもたらす、請求項22に記載の方法。
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WO2015080837A3 (en) | 2015-07-30 |
WO2015080837A2 (en) | 2015-06-04 |
BR112016011923A2 (pt) | 2017-08-08 |
CA3027396C (en) | 2020-07-21 |
EP3074363B1 (en) | 2021-05-05 |
US9511417B2 (en) | 2016-12-06 |
CN105745040A (zh) | 2016-07-06 |
CA2930571A1 (en) | 2015-06-04 |
CA2930571C (en) | 2019-02-12 |
US20150147186A1 (en) | 2015-05-28 |
JP6263264B2 (ja) | 2018-01-17 |
EP3074363A2 (en) | 2016-10-05 |
CN105745040B (zh) | 2019-01-11 |
CA3027396A1 (en) | 2015-06-04 |
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