JP7088612B2 - セラミックコアの製造方法及びインベストメント鋳造用セラミックコアの製造方法 - Google Patents
セラミックコアの製造方法及びインベストメント鋳造用セラミックコアの製造方法 Download PDFInfo
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Description
である。場合によっては、この金属は、従来のシリカ系セラミックコアと反応することがある。したがって、シリカが鋳造プロセス中に特定の金属と反応する可能性があるので、反応性金属の鋳造にシリカ含有コア材料を使用することは問題があることが知られている。
機械的強度を増加させる独特の特徴を有するセラミックコアを提供する。射出成形または他のタイプの従来の成形と同様に、従来の金属ダイまたはDCDをこのプロセスに使用することができる。
のシリカのムライトへの変換である。いくつかの実施形態では、硬化および焼成工程は、単一の炉内で単一の工程で行うことができる。他の実施形態では、焼成工程は、単一の炉で単一の工程で行うことができる。
)付近でのプラスチックダイの熱分解後にコア体に残り、炭素繊維はより高温になるまで酸化されないので、コア体を補強する。
[実施態様1]
インベストメント鋳造用セラミックコア(200)の製造方法であって、前記方法は、少なくとも、
セラミック粒子、バインダー、および炭素繊維(201)を含むスラリーを使い捨てダイ(100)に注入するステップを含む方法。
[実施態様2]
前記セラミックコア(200)の少なくとも一部は、タービンブレードの内面を画定する、実施態様1に記載の方法。
[実施態様3]
前記スラリーは、前記スラリーの20重量%を超えない濃度の炭素繊維(201)を含む、実施態様1に記載の方法。
[実施態様4]
前記炭素繊維(201)は200ミクロン以下の平均直径を有する、実施態様1に記載の方法。
[実施態様5]
前記炭素繊維(201)は100ミクロン以下の平均直径を有する、実施態様4に記載の方法。
[実施態様6]
前記炭素繊維(201)は、1:1より大きく100:1までのアスペクト比を有する、実施態様1に記載の方法。
[実施態様7]
前記炭素繊維(201)は、10:1より大きく100:1までのアスペクト比を有する、実施態様6に記載の方法。
[実施態様8]
前記使い捨てダイ(100)を除去する少なくとも1つの追加の加熱ステップをさらに含む、実施態様1に記載の方法。
[実施態様9]
前記炭素繊維(201)を実質的に除去する少なくとも1つの追加の加熱ステップをさらに含む、実施態様1に記載の方法。
[実施態様10]
セラミック粒子および繊維形状の空隙を含む焼成されたセラミックコア(200)であって、前記繊維形状の空隙は、前記コアの軸とほぼ整列している、セラミックコア(200)。
[実施態様11]
前記セラミックコア(200)の少なくとも一部は、タービンブレードの内面を画定する、実施態様10に記載のセラミックコア(200)。
[実施態様12]
前記空隙は200ミクロン以下の平均直径を有する、実施態様10に記載のセラミックコア(200)。
[実施態様13]
前記空隙は、100ミクロン以下の平均直径を有する、実施態様10に記載のセラミックコア(200)。
[実施態様14]
前記空隙は、1:1より大きく100:1までのアスペクト比を有する、実施態様10に記載のセラミックコア(200)。
[実施態様15]
前記空隙は、10:1より大きく100:1までのアスペクト比を有する、実施態様10に記載のセラミックコア(200)。
[実施態様16]
セラミック粒子、バインダー、および炭素繊維(201)を含む硬化したセラミックコア(200)であって、前記炭素繊維(201)は、前記コアの軸とほぼ整列している、硬化したセラミックコア(200)。
[実施態様17]
インベストメント鋳造用セラミックコア(200)の製造方法であって、前記方法は、少なくとも、
セラミック粒子、バインダー、および炭素繊維(201)の硬化した組成物を含む使い捨てダイ(100)を加熱するステップを含み、前記加熱するステップは、前記炭素繊維(201)を酸化して実質的に除去し、空隙を残す、方法。
200 セラミックコア
201 炭素繊維
Claims (19)
- セラミックコアの製造方法であって、
Al2O3-シロキサン系のスラリーを使い捨てダイに注入するステップであって、前記スラリーは、セラミック粒子、バインダー、および炭素繊維を含み、前記炭素繊維は、スラリーの注入の流れに沿って配向され、前記スラリーの20重量%を超えない濃度である、前記注入するステップと、
前記シロキサン系のスラリーの中のシリコンを、第1の温度および第1の時間での第1の焼成ステップで非晶質シリカに変換するステップと、
前記炭素繊維を除去して前記セラミックコアに空隙率40%を超える空隙を形成すると共に第2の温度および第2の時間での第2の焼成ステップにおいて、前記非晶質シリカと過剰なAl2O3とをムライトに変換するステップであって、前記第2の温度は前記第1の温度よりも高い、前記変換するステップと、
を含む方法。 - 前記第1の温度は、250°Cと750°Cとの間である、請求項1に記載の方法。
- 前記第2の温度は、1050°Cと1700°Cとの間である、請求項1に記載の方法。
- 前記第1の温度は、250°Cと750°Cとの間であり、前記第2の温度は、1050°Cと1700°Cとの間である、請求項1に記載の方法。
- 前記第1の時間は、10時間と20時間との間であり、前記第2の時間は、1時間と24時間との間である、請求項4に記載の方法。
- 前記第1の時間は、10時間と20時間との間である、請求項1に記載の方法。
- 前記第2の時間は、1時間と24時間との間である、請求項1に記載の方法。
- 前記シリコンを前記非晶質シリカに変換するステップよりも前に、前記スラリーを、25°Cと110°Cとの間の硬化温度及び1時間と24時間との硬化時間で、硬化するステップをさらに含む、請求項1に記載の方法。
- 前記セラミックコアの少なくとも一部は、タービンブレードの内面を画定するように、構成されている、請求項1に記載の方法。
- 前記炭素繊維は200ミクロン以下の平均直径を有する、請求項1に記載の方法。
- 前記炭素繊維は100ミクロン以下の平均直径を有する、請求項1に記載の方法。
- 前記炭素繊維は、1:1より大きく100:1までのアスペクト比を有する、請求項1に記載の方法。
- 前記炭素繊維は、10:1より大きく100:1までのアスペクト比を有する、請求項1に記載の方法。
- 前記使い捨てダイを除去するステップをさらに含む、請求項1に記載の方法。
- 前記第1の時間は、前記第2の時間より長い又は前記第2の時間に等しい、請求項1に記載の方法。
- インベストメント鋳造用のセラミックコアを製造する方法であって、
硬化された組成物を含む使い捨てダイを加熱することにより、セラミック粒子、バインダー、および炭素繊維のAl2O3-シロキサン系のスラリーから形成された前記硬化された組成物に、整列した空隙を形成し、前記炭素繊維が前記スラリーの20重量%を超えない濃度である、ステップを含み、
前記使い捨てダイを加熱することでは、前記炭素繊維を、酸化し且つ前記硬化した組成物から実質的に除去し、前記整列し、前記セラミックコアに空隙率40%を超える空隙を残す、
方法。 - 前記捨てダイを加熱することは、前記硬化された組成物において、非晶質シリカと過剰なAl2O3とをムライトに変換することをさらに含む、請求項16に記載の方法。
- 前記整列した空隙は、1050°Cと1700°Cとの間の温度で、形成される、請求項16に記載の方法。
- 前記捨てダイを加熱することは、1時間と24時間との間の時間及び1050°Cと1700°Cとの間の温度で行われる、請求項16に記載の方法。
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