JP2020513327A - 鋳物部品を製造するためのマルチピース一体型コア・シェル構造 - Google Patents
鋳物部品を製造するためのマルチピース一体型コア・シェル構造 Download PDFInfo
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D25/00—Special casting characterised by the nature of the product
- B22D25/02—Special casting characterised by the nature of the product by its peculiarity of shape; of works of art
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- 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
- B22C1/20—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 of organic agents
- B22C1/22—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 of organic agents of resins or rosins
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C13/00—Moulding machines for making moulds or cores of particular shapes
- B22C13/08—Moulding machines for making moulds or cores of particular shapes for shell moulds or shell cores
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C13/00—Moulding machines for making moulds or cores of particular shapes
- B22C13/12—Moulding machines for making moulds or cores of particular shapes for cores
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C21/00—Flasks; Accessories therefor
- B22C21/12—Accessories
- B22C21/14—Accessories for reinforcing or securing moulding materials or cores, e.g. gaggers, chaplets, pins, bars
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- 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
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- 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
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- 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
- B22C9/103—Multipart cores
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- 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
- B22C9/108—Installation of cores
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/12—Treating moulds or cores, e.g. drying, hardening
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- 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
- B22C9/24—Moulds for peculiarly-shaped castings for hollow articles
-
- 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
-
- 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
-
- 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
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B1/00—Producing shaped prefabricated articles from the material
- B28B1/001—Rapid manufacturing of 3D objects by additive depositing, agglomerating or laminating of material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B7/00—Moulds; Cores; Mandrels
- B28B7/34—Moulds, cores, or mandrels of special material, e.g. destructible materials
- B28B7/346—Manufacture of moulds
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
- B29C64/10—Processes of additive manufacturing
- B29C64/106—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
- B29C64/10—Processes of additive manufacturing
- B29C64/106—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
- B29C64/124—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
- B29C64/10—Processes of additive manufacturing
- B29C64/106—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
- B29C64/124—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified
- B29C64/129—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified characterised by the energy source therefor, e.g. by global irradiation combined with a mask
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
- B29C64/10—Processes of additive manufacturing
- B29C64/106—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
- B29C64/124—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified
- B29C64/129—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified characterised by the energy source therefor, e.g. by global irradiation combined with a mask
- B29C64/135—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified characterised by the energy source therefor, e.g. by global irradiation combined with a mask the energy source being concentrated, e.g. scanning lasers or focused light sources
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y10/00—Processes of additive manufacturing
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y70/00—Materials specially adapted for additive manufacturing
- B33Y70/10—Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y80/00—Products made by additive manufacturing
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
- F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
- F01D5/12—Blades
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
- F01D9/00—Stators
- F01D9/02—Nozzles; Nozzle boxes; Stator blades; Guide conduits, e.g. individual nozzles
- F01D9/04—Nozzles; Nozzle boxes; Stator blades; Guide conduits, e.g. individual nozzles forming ring or sector
- F01D9/041—Nozzles; Nozzle boxes; Stator blades; Guide conduits, e.g. individual nozzles forming ring or sector using blades
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- G—PHYSICS
- G03—PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
- G03F—PHOTOMECHANICAL PRODUCTION OF TEXTURED OR PATTERNED SURFACES, e.g. FOR PRINTING, FOR PROCESSING OF SEMICONDUCTOR DEVICES; MATERIALS THEREFOR; ORIGINALS THEREFOR; APPARATUS SPECIALLY ADAPTED THEREFOR
- G03F7/00—Photomechanical, e.g. photolithographic, production of textured or patterned surfaces, e.g. printing surfaces; Materials therefor, e.g. comprising photoresists; Apparatus specially adapted therefor
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- G—PHYSICS
- G03—PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
- G03F—PHOTOMECHANICAL PRODUCTION OF TEXTURED OR PATTERNED SURFACES, e.g. FOR PRINTING, FOR PROCESSING OF SEMICONDUCTOR DEVICES; MATERIALS THEREFOR; ORIGINALS THEREFOR; APPARATUS SPECIALLY ADAPTED THEREFOR
- G03F7/00—Photomechanical, e.g. photolithographic, production of textured or patterned surfaces, e.g. printing surfaces; Materials therefor, e.g. comprising photoresists; Apparatus specially adapted therefor
- G03F7/20—Exposure; Apparatus therefor
-
- 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
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P10/00—Technologies related to metal processing
- Y02P10/25—Process efficiency
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- General Physics & Mathematics (AREA)
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Abstract
Description
Claims (22)
- 第1コア部と第1シェル部とを備え、
前記第1コア部および前記第1シェル部は、少なくとも第2コア部および第2シェル部と接して前記第1コア部と前記第2コア部との間および前記第1シェル部と前記第2シェル部との間にキャビティを有するセラミック鋳型を形成し、
前記キャビティは、前記セラミック鋳型の鋳造および取り外しの際に鋳造部品を画定するようになっている、
部分セラミック鋳造鋳型。 - 前記鋳造部品はタービンブレードまたは静翼である、請求項1記載の部分セラミック鋳造鋳型。
- 前記第1コア部または前記第1シェル部は、前記第2コア部または前記第2シェル部上のインターロック機構と接するように構成された、少なくとも1つのインターロック機構を含む、請求項1に記載の部分セラミック鋳造鋳型。
- 前記インターロック機構は、第2の部分セラミック鋳造鋳型と締結するようになっている連結舌部または連結溝である、請求項3に記載の部分セラミック鋳造鋳型。
- 前記インターロック機構は、第2の部分セラミック鋳造鋳型と締結するようになっている蟻継ぎである、請求項3に記載の部分セラミック鋳造鋳型。
- 前記インターロック機構は、第2の部分セラミック鋳造鋳型と締結するようになっている連結ペグを備えた実接合である、請求項3に記載の部分セラミック鋳造鋳型。
- 前記第1シェル部は、前記第1コア部に面するピン支持体またはバンパーを備える、請求項1に記載の部分セラミック鋳造鋳型。
- 前記第1コア部は、前記第1コア部に面するピン支持体またはバンパーを備える、請求項1に記載の部分セラミック鋳造鋳型。
- 前記セラミック鋳型は、前記コア部と前記シェル部とを接合する複数の結合構造を含み、
前記結合構造は、前記鋳型を取り外す際に前記鋳造部品内に複数の穴を画定するように構成されている、
請求項1に記載の部分セラミック鋳造鋳型。 - 前記鋳造部品はタービンブレードまたは静翼である、請求項1記載の部分セラミック鋳造鋳型。
- 部分セラミック鋳型の製造方法であって、
(a)加工物の硬化部分を液体セラミックフォトポリマーと接触させることと、
(b)前記液体セラミックフォトポリマーに接する窓を通して前記硬化部分に隣接する前記液体セラミックフォトポリマーの一部を照射することと、
(c)未硬化の前記液体セラミックフォトポリマーから前記加工物を取り出すことと、
(d)部分セラミック鋳型の第1シェル部、および任意選択的に第1コア部、が形成されるまでステップ(a)〜(c)を繰り返すことと、を含み、
前記任意選択の第1コア部および前記第1シェル部は少なくとも任意選択の第2コア部および第2シェル部と接して、前記第1コア部および/または前記第2コア部と前記第1シェル部および前記第2シェル部との間にキャビティを含むツーピースセラミック鋳型を形成するように構成され、
前記キャビティは、前記セラミック鋳型の鋳造および取り外しの際に鋳造部品を画定するように構成される、
部分セラミック鋳型の製造方法。 - ステップ(d)の後に、前記ツーピースセラミック鋳型内に液体金属を注ぐこと、および前記液体金属を凝固させて前記鋳造部品を形成することを含むステップ(e)を含む、請求項11に記載の製造方法。
- ステップ(e)の後に、前記ツーピースセラミック鋳型を前記鋳造部品から取り外すことを含むステップ(f)を含む、請求項12に記載の製造方法。
- 前記ツーピースセラミック鋳型を前記鋳造部品から取り外すことは、力学的力と化学的浸出との組み合わせを含む、請求項13に記載の製造方法。
- 前記第1コア部または前記第1シェル部は、前記第2コア部または前記第2シェル部上のインターロック機構と接するように構成されている少なくとも1つのインターロック機構を含む、請求項11に記載の製造方法。
- 前記ツーピースセラミック鋳型は、前記コア部と前記シェル部とを接合する複数の結合構造を含み、
前記結合構造は、前記ツーピースセラミック鋳型を取り外す際に前記鋳造部品内に複数の穴を画定するように構成されている、
請求項11に記載の製造方法。 - 前記鋳造部品はタービンブレードまたは静翼である、請求項11に記載の製造方法。
- 前記第1シェル部は、前記第1コア部に面するピン支持体またはバンパーを備えている、請求項11に記載の製造方法。
- 前記第1コア部は、前記第1コア部に面するピン支持体またはバンパーを備えている、請求項11に記載の製造方法。
- 前記第1の部分セラミック鋳型は第1コア部を有し、前記第2の部分セラミック鋳型は第2コア部を有する、請求項11に記載の製造方法。
- 請求項11に記載の前記ツーピースセラミック鋳型を用いた鋳造部品の製造方法であって、
前記ツーピースセラミック鋳造鋳型に液体金属を注入するとともに前記液体金属を凝固させて前記鋳造部品を形成することと、
前記鋳造部品から前記ツーピースセラミック鋳型を取り外すことと、
を含む製造方法。 - 鋳造部品の製造方法であって、
ツーピースセラミック鋳型の第1コア部および第1シェル部を少なくとも第2コア部および第2シェル部と共に組み立てて、前記第1コア部および前記第2コア部と前記第1シェル部および前記第2シェル部との間に、前記ツーピースセラミック鋳型の鋳造および取り外しの際に前記鋳造部品の形状を画定するように構成されたキャビティを含む前記ツーピースセラミック鋳型を形成することと、
前記ツーピースセラミック鋳造鋳型に液体金属を注入するとともに、前記液体金属を凝固させて前記鋳造部品を形成することと、
前記鋳造部品から前記ツーピースセラミック鋳造鋳型を取り外すことと、
を含む製造方法。
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US15/377,796 | 2016-12-13 | ||
US15/377,796 US20180161866A1 (en) | 2016-12-13 | 2016-12-13 | Multi-piece integrated core-shell structure for making cast component |
PCT/US2017/056715 WO2018111397A1 (en) | 2016-12-13 | 2017-10-16 | Multi-piece integrated core-shell structure for making cast component |
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JP2020513327A true JP2020513327A (ja) | 2020-05-14 |
JP6940610B2 JP6940610B2 (ja) | 2021-09-29 |
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WO2018111397A1 (en) | 2018-06-21 |
US20200222978A1 (en) | 2020-07-16 |
US11351599B2 (en) | 2022-06-07 |
CN110087796A (zh) | 2019-08-02 |
EP3554739B1 (en) | 2022-08-03 |
US20180161866A1 (en) | 2018-06-14 |
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