JP2020515412A - セラミックの型を製造する方法、鋳造部品を製造する方法、及びセラミック鋳型 - Google Patents
セラミックの型を製造する方法、鋳造部品を製造する方法、及びセラミック鋳型 Download PDFInfo
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- 239000000919 ceramic Substances 0.000 title claims description 165
- 238000004519 manufacturing process Methods 0.000 title claims description 69
- 238000001816 cooling Methods 0.000 claims abstract description 95
- 238000002386 leaching Methods 0.000 claims abstract description 25
- 238000000034 method Methods 0.000 claims description 123
- 238000005266 casting Methods 0.000 claims description 66
- 238000005304 joining Methods 0.000 claims description 19
- 239000007788 liquid Substances 0.000 claims description 16
- 229910001338 liquidmetal Inorganic materials 0.000 claims description 16
- 239000000126 substance Substances 0.000 claims description 10
- 239000003513 alkali Substances 0.000 claims description 4
- 238000004891 communication Methods 0.000 claims description 4
- 239000012530 fluid Substances 0.000 claims description 4
- 230000001678 irradiating effect Effects 0.000 claims description 2
- 239000011258 core-shell material Substances 0.000 abstract description 75
- 238000005058 metal casting Methods 0.000 abstract description 5
- 239000013589 supplement Substances 0.000 abstract 1
- 239000000463 material Substances 0.000 description 58
- 230000008569 process Effects 0.000 description 32
- 239000002184 metal Substances 0.000 description 24
- 229910052751 metal Inorganic materials 0.000 description 24
- 238000002156 mixing Methods 0.000 description 24
- 229910000601 superalloy Inorganic materials 0.000 description 18
- 238000005495 investment casting Methods 0.000 description 16
- 239000000843 powder Substances 0.000 description 16
- 238000007639 printing Methods 0.000 description 12
- 238000013461 design Methods 0.000 description 10
- 238000012545 processing Methods 0.000 description 10
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 8
- 229920000642 polymer Polymers 0.000 description 8
- 230000015572 biosynthetic process Effects 0.000 description 6
- 239000013078 crystal Substances 0.000 description 6
- 238000007667 floating Methods 0.000 description 6
- 230000007246 mechanism Effects 0.000 description 6
- 239000011800 void material Substances 0.000 description 6
- 230000009471 action Effects 0.000 description 4
- 230000004913 activation Effects 0.000 description 4
- 238000005219 brazing Methods 0.000 description 4
- 239000003795 chemical substances by application Substances 0.000 description 4
- 238000010586 diagram Methods 0.000 description 4
- 238000005553 drilling Methods 0.000 description 4
- 238000005516 engineering process Methods 0.000 description 4
- 239000012467 final product Substances 0.000 description 4
- 238000012986 modification Methods 0.000 description 4
- 230000004048 modification Effects 0.000 description 4
- 229910052759 nickel Inorganic materials 0.000 description 4
- 238000010248 power generation Methods 0.000 description 4
- KUBDPQJOLOUJRM-UHFFFAOYSA-N 2-(chloromethyl)oxirane;4-[2-(4-hydroxyphenyl)propan-2-yl]phenol Chemical compound ClCC1CO1.C=1C=C(O)C=CC=1C(C)(C)C1=CC=C(O)C=C1 KUBDPQJOLOUJRM-UHFFFAOYSA-N 0.000 description 2
- 238000010146 3D printing Methods 0.000 description 2
- 229910010293 ceramic material Inorganic materials 0.000 description 2
- 238000007796 conventional method Methods 0.000 description 2
- 230000008878 coupling Effects 0.000 description 2
- 238000010168 coupling process Methods 0.000 description 2
- 238000005859 coupling reaction Methods 0.000 description 2
- 238000001723 curing Methods 0.000 description 2
- 238000007598 dipping method Methods 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- PCHJSUWPFVWCPO-UHFFFAOYSA-N gold Chemical compound [Au] PCHJSUWPFVWCPO-UHFFFAOYSA-N 0.000 description 2
- 239000010931 gold Substances 0.000 description 2
- 229910052737 gold Inorganic materials 0.000 description 2
- 238000010438 heat treatment Methods 0.000 description 2
- 229910001026 inconel Inorganic materials 0.000 description 2
- 230000002452 interceptive effect Effects 0.000 description 2
- 238000003754 machining Methods 0.000 description 2
- 239000007769 metal material Substances 0.000 description 2
- 239000000203 mixture Substances 0.000 description 2
- 238000000016 photochemical curing Methods 0.000 description 2
- 239000002861 polymer material Substances 0.000 description 2
- 238000006116 polymerization reaction Methods 0.000 description 2
- 230000001681 protective effect Effects 0.000 description 2
- 239000011347 resin Substances 0.000 description 2
- 229920005989 resin Polymers 0.000 description 2
- 230000000717 retained effect Effects 0.000 description 2
- 238000012546 transfer Methods 0.000 description 2
Classifications
-
- 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
-
- 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
- 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
- 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
- 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
-
- 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
-
- 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
- B33Y80/00—Products made by additive manufacturing
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/757—Moulds, cores, dies
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Manufacturing & Machinery (AREA)
- Materials Engineering (AREA)
- Physics & Mathematics (AREA)
- Optics & Photonics (AREA)
- Ceramic Engineering (AREA)
- Molds, Cores, And Manufacturing Methods Thereof (AREA)
- Turbine Rotor Nozzle Sealing (AREA)
- Mold Materials And Core Materials (AREA)
- Casting Devices For Molds (AREA)
Abstract
Description
しかし、これらのシステムの利用可能な印刷の分解能は、鋳造の最終的な製造物において有効な冷却穴として役立てるのに十分に小さいサイズのフィラメントを製造する能力を著しく制限する。
しかし、これらのシステムの利用可能な印刷の分解能は、鋳造の最終的な製造物において有効な冷却穴として役立てるのに十分に小さいサイズのフィラメントを製造する能力を著しく制限する。
Claims (20)
- セラミックの型を製造する方法であって、
(a)加工物の硬化部分を液状セラミックフォトポリマーと接触させること、
(b)前記液状セラミックフォトポリマーに接触する窓を通して前記硬化部分に隣接する前記液状セラミックフォトポリマーの一部を照射すること、
(c)未硬化の液状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、
(d)セラミックの型が形成されるまで(a)〜(c)を繰り返すこと、
を含み、
前記セラミックの型が、コア部とシェル部とであって、前記コア部と前記シェル部との間に少なくとも1つのキャビティを有し、前記キャビティが、前記セラミックの型の鋳造及び取り外しの際に鋳造部品の形状を画定するように適合される、コア部とシェル部と、を含む、
方法。 - 前記方法が、(d)の後に、液状金属を鋳造用の型に注ぎ込み、前記液状金属を凝固させて前記鋳造部品を形成することを含む(e)を含む、請求項1に記載の方法。
- 前記方法が、(e)の後に、前記鋳造部品から前記型を取り外すことを含む(f)を含む、請求項2に記載の方法。
- 前記鋳造部品から前記型を取り外すことが、機械的な力と化学的な浸出との組み合わせを含む、請求項3に記載の方法。
- 前記鋳造部品から前記型をアルカリに浸して化学的な浸出によって除去する、請求項4に記載の方法。
- 前記セラミックの型が、前記コア部と前記シェル部とを接合する複数のフィラメントを含み、前記フィラメントが、前記型の取り外し時に前記鋳造部品に複数の穴を画定するように適合され、各フィラメントがコアとシェルとの間の全長にまたがる、請求項1に記載の方法。
- 前記鋳造部品がタービンブレード又はステータベーンである、請求項1に記載の方法。
- 前記鋳造部品がタービンブレード又はステータベーンであり、前記セラミックの型が、前記コア部とシェル部とを接合する複数のフィラメントを含み、各フィラメントがコアとシェルとの間にまたがり、前記フィラメントは、前記型を取り出すと、前記タービンブレード又は前記ステータベーンに複数の冷却穴を画定するよう適合される、請求項1に記載の方法。
- 前記セラミックの型が、前記コア部と前記シェル部とを接合する複数のフィラメントを含み、各フィラメントがコアとシェルとの間にまたがり、前記フィラメントは0.01〜2mm2の範囲の断面積を有する、請求項1に記載の方法。
- 鋳造部品を製造する方法であって、
セラミック鋳型に液状金属を注入し、前記液状金属を凝固させて前記鋳造部品を形成することであって、前記セラミック鋳型は、コア部とシェル部とであって、前記コア部と前記シェル部との間に少なくとも1つのキャビティを含み、前記キャビティが、セラミックの型の鋳造及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適合される、コア部とシェル部とを含み、前記コア部と前記シェル部とを接合する複数のフィラメントであって、各フィラメントがコアとシェルとの間にまたがり、前記型の取り出し外し時に前記鋳造部品における複数の穴を画定するよう適合され、前記セラミックの型が、前記コア部と前記シェル部とを接合する複数のフィラメントを含み、各フィラメントが前記コアとシェルとの間にまたがり、前記フィラメントは0.01〜2mm2の範囲の断面積を有する、フィラメントを鋳型がさらに含む、形成すること、
前記フィラメントによって設けられた前記鋳造部品の前記穴を通してセラミックコアの少なくとも一部を浸出させることによって前記鋳造部品から前記セラミック鋳型を取り外すこと、
を含む方法。 - 前記鋳造部品から前記セラミック鋳型を取り外すことが、機械的な力と化学的な浸出との組み合わせを含む、請求項10に記載の方法。
- 前記鋳造部品から前記型をアルカリに浸して化学的な浸出によって除去する、請求項11に記載の方法。
- 前記鋳造部品がタービンブレード又はステータベーンである、請求項10に記載の方法。
- 前記鋳造部品がタービンブレード又はステータベーンであり、前記セラミックの型が、前記コア部とシェル部とを接合する複数のフィラメントを含み、各フィラメントが前記コアとシェルとの間にまたがり、前記フィラメントは、前記型を取り出すと、前記タービンブレード又は前記ステータベーンに複数の冷却穴を画定するよう適合される、請求項10に記載の方法。
- 前記セラミックの型が、前記コア部と前記シェル部とを接合する複数のフィラメントを含み、各フィラメントが前記コアと前記シェルとの間にまたがり、前記フィラメントは0.01〜2mm2の範囲の断面積を有する、請求項10に記載の方法。
- セラミック鋳型であって、
コア部とシェル部とであって、前記コア部と前記シェル部との間に少なくとも1つのキャビティを含み、前記キャビティが、セラミックの型の鋳造及び取り外しの際に鋳造部品の形状を画定するように適合される、コア部とシェル部と、
前記コア部と前記シェル部とを接合する複数のフィラメントであって、各フィラメントがコアとシェルとの間にまたがり、前記型の取り出し外し時に前記コア部により画定される前記鋳造部品内のキャビティと前記鋳造部品の外面との間に流体連通をもたらす複数の穴を画定するよう適合され、前記セラミックの型が、前記コア部と前記シェル部とを接合する複数のフィラメントを含み、各フィラメントが前記コアとシェルとの間にまたがり、前記フィラメントは0.01〜2mm2の範囲の断面積を有する、フィラメントと、
を含む、セラミック鋳型。 - 前記鋳造部品がタービンブレード又はステータベーンであり、前記コア部とシェル部とを接合する前記複数のフィラメントは、前記型の取り外し時に前記タービンブレード又は前記ステータベーンに複数の冷却穴を画定する、請求項16に記載のセラミック鋳型。
- 前記コア部とシェル部を接合する前記複数のフィラメントは、0.01〜2mm2の範囲の断面積を有する、請求項16に記載のセラミック鋳型。
- 前記セラミックが光重合セラミックである、請求項16に記載のセラミック鋳型。
- 前記セラミックが硬化した光重合セラミックである、請求項16に記載のセラミック鋳型。
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US15/377,728 | 2016-12-13 | ||
US15/377,728 US20180161854A1 (en) | 2016-12-13 | 2016-12-13 | Integrated casting core-shell structure |
PCT/US2017/058549 WO2018111415A1 (en) | 2016-12-13 | 2017-10-26 | Integrated casting core-shell structure |
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EP (1) | EP3554738A1 (ja) |
JP (1) | JP7327742B2 (ja) |
CN (1) | CN110072645B (ja) |
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CN205736046U (zh) * | 2016-06-20 | 2016-11-30 | 深圳市未来工场科技有限公司 | 一种dlp技术的3d打印机装置 |
CN205736050U (zh) * | 2016-06-27 | 2016-11-30 | 西安科技大学 | 一种用于制备三维光弹性模型的紫外面曝光快速成型装置 |
US20180161856A1 (en) * | 2016-12-13 | 2018-06-14 | General Electric Company | Integrated casting core-shell structure and filter for making cast component |
US20180161853A1 (en) * | 2016-12-13 | 2018-06-14 | General Electric Company | Integrated casting core-shell structure with floating tip plenum |
US20180161852A1 (en) * | 2016-12-13 | 2018-06-14 | General Electric Company | Integrated casting core-shell structure with printed tubes for making cast component |
-
2016
- 2016-12-13 US US15/377,728 patent/US20180161854A1/en not_active Abandoned
-
2017
- 2017-10-26 WO PCT/US2017/058549 patent/WO2018111415A1/en unknown
- 2017-10-26 JP JP2019531675A patent/JP7327742B2/ja active Active
- 2017-10-26 CA CA3045623A patent/CA3045623C/en active Active
- 2017-10-26 CN CN201780076795.6A patent/CN110072645B/zh active Active
- 2017-10-26 EP EP17797808.7A patent/EP3554738A1/en active Pending
Patent Citations (2)
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JP2003520134A (ja) * | 1998-11-20 | 2003-07-02 | ロールス−ロイス・コーポレーション | 鋳造部品を製造する方法及び装置 |
JP2016522750A (ja) * | 2013-04-19 | 2016-08-04 | ユナイテッド テクノロジーズ コーポレイションUnited Technologies Corporation | 欠陥を直し微細構造を改変させるための付加製造された部品の再形成 |
Also Published As
Publication number | Publication date |
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CA3045623C (en) | 2023-10-03 |
WO2018111415A1 (en) | 2018-06-21 |
EP3554738A1 (en) | 2019-10-23 |
US20180161854A1 (en) | 2018-06-14 |
JP7327742B2 (ja) | 2023-08-16 |
CN110072645B (zh) | 2022-06-10 |
CN110072645A (zh) | 2019-07-30 |
CA3045623A1 (en) | 2018-06-21 |
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