US20090169415A1 - Mold and manufacturing method thereof, and molded article using the mold - Google Patents

Mold and manufacturing method thereof, and molded article using the mold Download PDF

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Publication number
US20090169415A1
US20090169415A1 US12/065,692 US6569206A US2009169415A1 US 20090169415 A1 US20090169415 A1 US 20090169415A1 US 6569206 A US6569206 A US 6569206A US 2009169415 A1 US2009169415 A1 US 2009169415A1
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mold
initial layer
titanium
molded article
forming
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English (en)
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Kazuyoshi Chikugo
Shigeyuki Sato
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IHI Corp
IHI Castings Co Ltd
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IHI Corp
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Assigned to IHI CORPORATION, ISHIKAWAJIMA PRECISION CASTINGS CO., LTD. reassignment IHI CORPORATION ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: CHIKUGO, KAZUYOSHI, SATO, SHIGEYUKI
Assigned to IHI CASTINGS CO., LTD. reassignment IHI CASTINGS CO., LTD. CHANGE OF NAME (SEE DOCUMENT FOR DETAILS). Assignors: ISHIKAWAJIMA PRECISION CASTINGS CO., LTD.
Publication of US20090169415A1 publication Critical patent/US20090169415A1/en
Abandoned legal-status Critical Current

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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
    • B22D21/00—Casting non-ferrous metals or metallic compounds so far as their metallurgical properties are of importance for the casting procedure; Selection of compositions therefor
    • B22D21/002—Castings of light metals
    • B22D21/005—Castings of light metals with high melting point, e.g. Be 1280 degrees C, Ti 1725 degrees C
    • 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
    • B22C1/00—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds
    • B22C1/02—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by additives for special purposes, e.g. indicators, breakdown additives
    • B22C1/04—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by additives for special purposes, e.g. indicators, breakdown additives for protection of the casting, e.g. against decarbonisation
    • B22C1/06—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by additives for special purposes, e.g. indicators, breakdown additives for protection of the casting, e.g. against decarbonisation for casting extremely oxidisable metals
    • 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
    • B22C1/02—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by additives for special purposes, e.g. indicators, breakdown additives
    • B22C1/08—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by additives for special purposes, e.g. indicators, breakdown additives for decreasing shrinkage of the mould, e.g. for investment casting
    • 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
    • B22C1/18—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 inorganic agents
    • B22C1/186—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 inorganic agents contaming ammonium or metal silicates, silica sols
    • 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
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D21/00—Casting non-ferrous metals or metallic compounds so far as their metallurgical properties are of importance for the casting procedure; Selection of compositions therefor
    • B22D21/02—Casting exceedingly oxidisable non-ferrous metals, e.g. in inert atmosphere

Definitions

  • the present invention relates to a mold used for manufacturing a molded article of a titanium-aluminum alloy or a titanium alloy, a method for manufacturing the same, and a molded article using the mold.
  • Titanium-aluminum alloys composed of titanium aluminide (TiAl), which is an intermetallic compound of Ti and Al have features such as small weight and high strength. For this reason, titanium-aluminum alloys are promising materials for turbochargers for automobile engines and rotary member for gas turbine engines or aircraft jet engines.
  • titanium alloys have good corrosion resistance, small weight and biocompatibility, they have been widely used for automobiles, motorcycles, sports and leisure goods, artificial bones, artificial teeth, and the like.
  • ⁇ case a needle-like modified layer (oxygen-rich layer, surface hardened layer) that is called ⁇ case is sometimes formed in the surface layer portion of the obtained molded articles.
  • the ⁇ case has higher hardness and lower machinability than the ⁇ phase of the matrix phase. Therefore, where the ⁇ case layer is too thick, a long time is required for chemical milling or mechanical cutting, causing increase in production cost and decrease in productivity.
  • molds described in Japanese Patent Application Laid-open No. H5-123820, Japanese Patent Application Laid-open No. 2003-225738, Japanese Patent Application Laid-open No. H 5-277624 and Japanese Patent Application Laid-open No. H 6-292940 above were designed for titanium alloys, and these molds have been often diverted as molds for titanium-aluminum alloys.
  • titanium-aluminum alloys and titanium alloys Because of high activity to titanium-aluminum alloys and titanium alloys, the reaction of molten alloy and mold has to be taken into account. In particular, because titanium-aluminum alloys have higher reactivity with molds than titanium alloys, it is important to inhibit this reactivity. This is because, both Ti and Al are active metals, but the activity of Al is higher than that of Ti, and also because titanium-aluminum alloys have a melting point higher than titanium alloys.
  • the mold is composed of a ceramic and mainly comprises a filler and a binder for increasing bonding between the filler particles.
  • constituent materials with low reactivity include zirconium oxide (zirconia), yttrium oxide (yttria), and calcium oxide (calcia) as the filler, and zirconia sol and organic binders (for example, resins) as the binder.
  • Zirconia sol is expensive to be used as the binder on the industrial scale and has low strength at a temperature close to room temperature. Therefore, a separate binder is required to maintain the strength at room temperature. Further, organic binders are decomposed at a high temperature, and a separate binder has to be used to maintain the strength at a high temperature. As a result, the mold cost rises.
  • the mold in accordance with the present invention that attains the above-described object is a mold for manufacturing a molded article of a titanium-aluminum alloy or a titanium alloy, wherein at least an initial layer of a cavity surface of a mold body is formed of a calcined product of a slurry comprising a filler having cerium oxide as a main component and a binder having silica sol as a main component.
  • the initial layer and a second layer of the cavity surface of the mold body be formed from the calcined product of the slurry.
  • the mold is a shell mold or a solid mold.
  • a method for manufacturing a mold in accordance with the present invention is for manufacturing a molded article of a titanium-aluminum alloy or a titanium alloy, comprising:
  • an initial layer slurry film by applying an initial layer slurry comprising a filler having cerium oxide as a main component and a binder having silica sol as a main component to a surface of a wax mold that is an evaporative pattern mold and by drying thereof;
  • the step of forming the initial layer slurry film is preferably repeated again as a step for forming the second slurry film.
  • the method for manufacturing a mold in accordance with the present invention is for manufacturing a molded article of a titanium-aluminum alloy or a titanium alloy, comprising:
  • a step of forming a block body of an initial layer slurry by applying an initial layer slurry comprising a filler having cerium oxide as a main component and a binder having silica sol as a main component to a surface of a wax mold that is an evaporative pattern mold and by drying thereof,
  • a step of forming a solid mold by performing a calcination treatment with respect to the mold precursor to solidify the block body.
  • the method for manufacturing a mold in accordance with the present invention is for manufacturing a molded article of a titanium-aluminum alloy or a titanium alloy, comprising:
  • an initial layer slurry film by applying an initial layer slurry comprising a filler having cerium oxide as a main component and a binder having silica sol as a main component to a surface of a wax mold that is an evaporative pattern mold and by drying thereof;
  • a step of forming a solid mold by performing a calcination treatment with respect to the mold precursor to solidify the initial layer slurry film and the block body.
  • the step of forming the initial layer slurry film be repeated again after the step of forming the initial layer slurry film, and the block body of the last layer slurry be formed around the initial layer slurry film having a two-layer structure.
  • the titanium-aluminum alloy molded article in accordance with the present invention is formed by casting in use of the above-described shell mold or solid mold.
  • the titanium-aluminum alloy molded article in accordance with the present invention is a titanium alloy molded article that is formed by casting in use of the above-described shell mold or solid mold, wherein a thickness of an ⁇ case layer in the surface layer portion of the as-cast material is less than 300 ⁇ m.
  • the mold in accordance with the present invention demonstrates an excellent effect in making it possible to obtain a molded article of a titanium-aluminum alloy with good surface state even as-cast material or a molded article of a titanium alloy with reduced occurrence of ⁇ case in the surface layer.
  • FIG. 1 is a cross-sectional view of a wax mold for use in the manufacture of a mold of one preferred embodiment of the present invention.
  • FIG. 2 illustrates a state after a slurry film has been formed around the wax mold in the process for manufacturing the mold of one preferred embodiment of the present invention.
  • FIG. 3 illustrates the state after wax removal in the process for manufacturing the mold of one preferred embodiment of the present invention.
  • FIG. 4 is a cross sectional view of the mold in one preferred embodiment of the present invention.
  • FIG. 5 illustrates the state in which a melt is poured into a mold cavity shown in FIG. 4 .
  • FIG. 6 is a cross sectional view of a molded article formed by casting using the mold shown in FIG. 4 .
  • FIG. 7 is a cross-sectional view of a wax mold used in the manufacture of a mold of another preferred embodiment of the present invention.
  • FIG. 8 illustrates a state after a slurry film has been formed around the wax mold in the process for manufacturing the mold of another preferred embodiment of the present invention.
  • FIG. 9 illustrates the formation of a slurry block body around a slurry film in the process for manufacturing the mold of another preferred embodiment of the present invention.
  • FIG. 10 illustrates a state after the slurry block body has been formed in the process for manufacturing the mold of another preferred embodiment of the present invention.
  • FIG. 11 illustrates a state after the wax has been removed in the process for manufacturing the mold of another preferred embodiment of the present invention.
  • FIG. 12 is a cross sectional view of a mold of another preferred embodiment of the present invention.
  • FIG. 13 illustrates a state in which a melt has been poured into the cavity of the mold shown in FIG. 12 .
  • FIG. 14 is a cross sectional view of a molded article that is formed by casting using the mold shown in FIG. 12 .
  • FIG. 15 is a planar observation view of a portion of a titanium-aluminum alloy molded article formed by casting by using a mold of one preferred embodiment of the present invention.
  • FIG. 16 is an enlarged view of the main portion 16 shown in FIG. 15 .
  • FIG. 17 is a planar observation view of a portion of a titanium-aluminum alloy molded article formed by casting by using the conventional mold.
  • FIG. 18 is an enlarged view of the main portion 18 shown in FIG. 17 .
  • FIG. 19 is a cross-sectional view illustrating an adhesion state of the initial layer slurry and the wax mold when the filler/binder ratio in the initial layer slurry is 1.8.
  • FIG. 20 is a cross-sectional view illustrating an adhesion state of the initial layer slurry and the wax mold when the filler/binder ratio in the initial layer slurry is 2.0.
  • FIG. 21 is a cross-sectional view illustrating an adhesion state of the initial layer slurry and the wax mold when the filler/binder ratio in the initial layer slurry is 3.0.
  • FIG. 22 is a cross-sectional observation view of a titanium alloy molded article formed by casting using a shell mold of one preferred embodiment of the present invention.
  • FIG. 23 is a cross-sectional observation view of a titanium alloy molded article formed by casting using a conventional shell mold.
  • FIG. 24 is a cross-sectional observation view of a titanium alloy molded article formed by casting using a solid mold of another preferred embodiment of the present invention.
  • FIG. 25 is a cross-sectional observation view of a titanium alloy molded article formed by casting using a conventional solid mold.
  • colloidal silica (silica sol) has been used as a binder for casting molds for Ni-based alloys, Co-based alloys, and Fe-based alloys.
  • Silica sol features chemical stability (low activity), low industrial cost, and a high strength from room temperature to a high temperature.
  • silica sol is highly reactive with titanium-aluminum alloys and titanium alloys. For this reason, silica sol has been conventionally considered unsuitable for use as a binder for molds for titanium-aluminum alloys and titanium alloys.
  • FIG. 4 A cross sectional view of a mold of one preferred embodiment of the present invention is shown in FIG. 4 .
  • a mold (shell mold) 40 of the present embodiment at least an initial layer (in FIG. 4 , two layers, that is, an initial layer 44 a and a second layer 44 b of a cavity surface 43 ) of a surface (referred to hereinbelow as “cavity surface”) 43 adjacent to a cavity 32 of a mold body 41 is formed from a calcined product (referred to hereinbelow as a cerium oxide-silica sol calcined product) of a slurry composed of a filler comprising cerium oxide as the main component and a binder comprising silica sol as the main component.
  • a calcined product referred to hereinbelow as a cerium oxide-silica sol calcined product
  • the mold body 41 has a multilayer structure comprising the initial layer (surfacemost layer) 44 a , the second layer 44 b , a third layer 44 c . . . .
  • the slurry calcined product constituting the third layer 44 c and subsequent layers may be the same as, or different from the cerium oxide-silica sol calcined product constituting the initial layer 44 a and second layer 44 b .
  • a composition identical to that of the usual mold for example, a calcined product of a slurry composed of a filler comprising at least one selected from zirconia, alumina, silica, mullite, zircon, and yttria as the main component and a binder comprising zirconia sol as the main component
  • a composition identical to that of the usual mold for example, a calcined product of a slurry composed of a filler comprising at least one selected from zirconia, alumina, silica, mullite, zircon, and yttria as the main component and a binder comprising zirconia sol as the main component
  • the major part for example, 75 wt. % or more, preferably 80 wt. % or more of the filler of the initial layer, is cerium oxide, and the remainder is composed of at least one oxide selected from zirconia, alumina, silica mullite, zircon, or yttria. It goes without saying, that the filler may be composed only of cerium oxide (filler containing 100 wt. % cerium oxide).
  • the binder for example comprises silica sol (20 to 50% aqueous solution of silica sol) at 10 to 100 wt. %, preferably 50 to 100 wt. % of the entire binder, the remainder being composed of zirconia sol, yttria sol, alumina sol, or an organic binder.
  • At least the viscosity of the initial layer slurry is adjusted by the filler (gram)/binder (gram) ratio to a range of 2-4, preferably 2.5 to 3.5. Where the slurry viscosity is low, the slurry does not remain in the mold (the below-described wax mold 10 ) and peeling occurs.
  • FIG. 19 shows that when the filler/binder ratio is 1.8, peeling occurs
  • FIG. 20 shows that when the filler/binder ratio is 2.0, peeling is about to start.
  • FIG. 21 when the filler/binder ratio is 3.0, peeling does not occur and a uniform film is obtained.
  • the filler/binder ratio is taken to be equal to or below 4.0.
  • the explanation is conducted with respect to the case in which the mold body 41 has a three-layer structure, but the present invention is not limited to such configuration.
  • the mold body 41 can have a two-layer structure or a structure comprising four or more layers.
  • the explanation is conducted with respect to the case in which the initial layer 44 a and the second layer 44 b are composed of the cerium oxide-silica sol calcined product (materials of the same type), but the present invention is not limited to such configuration.
  • the thickness of the initial layer 44 a is sufficiently large (for example, in the case where the thickness of the initial layer 44 a is 500 ⁇ m or more), it is preferred that only the initial layer 44 a be formed from cerium oxide-silica sol calcined product, and that the second and subsequent layers be from the same material as the usual molds (for example, a calcined product of a slurry composed of a filler comprising zirconium oxide as the main component and a binder comprising zirconia sol as the main component), and with consideration for coating workability, a slurry may be used in which the filler/binder ratio is decreased and viscosity is reduced by comparison with those of the initial layer.
  • a wax mold 10 of the same shape and size as a target precision molded article is prepared in advance.
  • an initial layer slurry is coated around the wax mold 10 , then the initial layer stucco is coated, and then dried, to form an initial layer slurry film 24 a , as shown in FIG. 2 .
  • a second layer slurry is coated around the initial layer slurry film 24 a , the second layer stucco is coated, and then dried, to form the second layer slurry film 24 b .
  • the initial layer slurry and the second layer slurry are identical.
  • the initial layer slurry film 24 a and the second layer slurry film 24 b constitute a two-layer structure of the initial layer slurry film 24 a.
  • the initial layer slurry and the second layer slurry are prepared, for example, by mixing 1 kg of a binder comprising silica sol as the main component with 2 to 4 kg of a filler comprising cerium oxide as the main component.
  • a binder comprising silica sol as the main component
  • a filler comprising cerium oxide
  • at least one compound selected from zirconia, alumina, silica, mullite, and yttria of about #60 to 160 mesh can be used as the stucco (refractory particles that are scattered over, and caused to adhere to the slurry surface) of the initial layer and second layer, but no specific limitation is placed on the particle size and material thereof.
  • a dipping method, a blowing method, and a coating method can be used for applying the slurry, but the dipping method is preferred.
  • a third layer slurry is then coated around the second layer slurry film 24 b , then the third layer stucco is coated, and then dried to form a third layer slurry film 24 c .
  • the steps of forming the slurry films of the third and subsequent layers are performed appropriately and repeatedly as necessary. As a result, the thickness of the entire slurry film is controlled to the desired thickness. No specific limitation is placed on the third layer slurry and the slurry of subsequent layers, and also on the constituent materials of the third layer stucco and the stucco of subsequent layers, and any slurry and stucco that have been usually used for shell molds can be applied.
  • the wax of the wax pattern 10 is then removed using steam, whereby a mold precursor 30 is obtained, as shown in FIG. 3 .
  • the mold precursor 30 has a cavity 32 inside the precursor body 31 configured of three layers of slurry films 24 a , 24 b , 24 c.
  • the mold (shell mold) 40 of the present embodiment is then obtained, as shown in FIG. 4 , by subjecting the mold precursor 30 to calcination treatment.
  • the shell mold 40 has the cavity 32 inside the mold body 41 configured of three layers: initial layer 44 a , second layer 44 b , and third layer 44 c.
  • a melt 50 of a titanium-aluminum alloy or titanium alloy is poured into the cavity 32 of the shell mold 40 and casting is performed.
  • the shell mold 40 is then cooled to solidify the melt 50 , thereby completing the casting process.
  • a cast body is formed inside the shell mold 40 .
  • the shell mold 40 is then dipped into a high-temperature alkali bath or the like, the shell, that is, the mold body 41 is dissolved and removed, and knockout is performed to obtain a molded article 60 of a titanium-aluminum alloy or a titanium alloy, as shown in FIG. 6 .
  • a physical method for example, blast cleaning
  • Sandblasting, shot blasting, or water jet (blowing of high-pressure water) may be used for blast cleaning.
  • Shakeout may be also used as a physical method other than blast cleaning.
  • the initial layer 44 a and the second layer 44 b of the cavity surface 43 of the mold body 41 that comes into direct contact with the melt 50 of titanium-aluminum alloy is formed from the cerium oxide-silica sol calcined product.
  • cerium oxide used as the main component of the filler of the shell mold 40 is hardly a stable oxide in comparison with zirconia or yttria. This is also clear from the comparison of free energies.
  • cerium oxide demonstrates excellent stability with respect to Ti and neither reacts directly with Ti nor is reduced by the melt 50 of titanium-aluminum alloy poured into the cavity 32 of the shell mold 40 .
  • the inventors noticed this specific feature of cerium oxide.
  • cerium oxide as the main component of the filler of the mold body 41 , it is possible to prevent the melt 50 of titanium-aluminum alloy from reacting with the mold body 41 and oxidizing inside the cavity 32 .
  • silica sol that is used as the main component of the binder of the mold body 41 usually reacts vigorously with the melt 50 of titanium-aluminum alloy.
  • cerium oxide as the main component of the filler, as in the shell mold 40 of the present embodiment, it is possible to prevent a vigorous reaction between silica sol and titanium-aluminum alloy even when silica sol is used for the binder.
  • silica sol is chemically stable (low activity), industrially inexpensive, and has a high strength within a range from room temperature to a high temperature, when silica sol is used, the strength is maintained with single sol and it is not necessary to use other sols or organic binders for the binder.
  • cerium oxide is less expensive than zirconia or yttria
  • using cerium oxide as the main component of the filler of the shell mold 40 makes it possible to reduce the cost of materials for the mold.
  • silica sol has been used as a binder for the usual molds (for example, molds for Ni-based alloys)
  • silica sol is used as the main component of the binder for the shell mold 40 , it is possible to expect a significant cost reduction since the binder can be shared. Because of these factors, an inexpensive shell mold 40 can be obtained.
  • the initial layer 44 a and second layer 44 b of the cavity surface 43 of the mold body 41 By forming the initial layer 44 a and second layer 44 b of the cavity surface 43 of the mold body 41 from the cerium oxide-silica sol calcined product, it is possible to suppress reliably (or almost reliably) the oxidation of titanium-aluminum alloy and the reaction between silica sol and titanium-aluminum alloy, to suppress the formation of a layer containing a large amount of oxygen on the surface of the molded article 60 , and to inhibit the adhesion (baking) of the mold body 41 to the surface of the molded article 60 .
  • the titanium-aluminum alloy molded article 150 that was formed by casting using the shell mold 40 of the present embodiment, practically no baking of the mold body to the surface of the molded article was observed.
  • the titanium-aluminum alloy molded article 150 had beautiful surface appearance and a smooth surface.
  • the titanium-aluminum alloy molded article 160 formed by casting using zirconia as the main component of the filler and silica sol as the main component of the binder of the mold a large amount of baked material 161 of the mold body appeared on the surface of the molded article.
  • the titanium-aluminum alloy molded article 160 had poor surface appearance, a rough surface, and poor surface state.
  • the titanium-aluminum alloy molded article 150 formed by casting using the shell mold 40 of the present embodiment practically no mold body is baked to the molded article surface. Therefore, good surface state can be obtained by simple blast cleaning.
  • the titanium-aluminum alloy molded article 150 has an average surface roughness of an as-molded article of 200 ⁇ m or less, preferably 50 ⁇ m or less. Therefore, even the as-cast titanium-aluminum alloy molded article 150 has a sufficiently good surface state and does not require surface finishing treatment such as chemical milling or mechanical cutting (or required only very small surface finishing). Therefore, the titanium-aluminum alloy molded article 150 makes it possible to reduce the number of production steps, reduce the production cost, and improve productivity in comparison with the conventional titanium-aluminum alloy molded article 160 .
  • the shell mold 40 of the present embodiment can be manufactured by changing the formation steps of the initial layer slurry film 24 a and the second layer slurry film 24 b (or only the initial layer slurry film 24 a ). Therefore, the shell mold 40 of the present embodiment can be manufactured without substantial changes in the already existing production line for the conventional shell mold and, as a consequence, the increase in production cost can be suppressed.
  • the thickness of the ⁇ case layer occurring in the surface layer portion of the obtained molded article 60 is thin, which is less than 300 ⁇ m, preferably less than 250 ⁇ m.
  • the thickness of the ⁇ case layer occurring in the surface layer portion was about 220 ⁇ m.
  • the thickness of the ⁇ case layer occurring in the surface layer portion was about 500 ⁇ m. Therefore, it is clear that the thickness of the ⁇ case layer in the titanium alloy molded article 220 is less than half that in the titanium alloy molded article 230 .
  • the occurrence of the ⁇ case layer in the surface layer portion is reduced. Therefore, a time required for surface treatment (chemical milling, mechanical cutting, or the like) is shortened in comparison with that for the conventional titanium alloy molded article 230 . Accordingly, productivity of the titanium alloy molded article 220 is increased and the production cost of the titanium alloy molded article 220 can be reduced. Further, because no significant surface treatment is required for the titanium alloy molded article 220 to obtain the final product and the difference in dimensions between the titanium alloy molded article 220 and the final product is small, the material yield is good and the material cost of the titanium alloy molded article 220 can be reduced.
  • the mold 40 of the present embodiment is suitable as a mold for precision molded articles.
  • titanium-aluminum alloy precision molded articles include rotary members for turbochargers for automobile engines, gas turbine engines, and aircraft jet engines, and also heat-resistant tools.
  • titanium alloy precision molded articles include automobile and motorcycle parts, sports and leisure articles, artificial bones, artificial teeth, and heat exchangers.
  • FIG. 12 A cross sectional view of the mold of another preferred embodiment of the present invention is shown in FIG. 12 .
  • the initial layer in the mold (solid mold) 120 of the present embodiment, at least the initial layer (in FIG. 12 , two layers: an initial layer 44 a and a second layer 44 b of a cavity surface 123 ) of the cavity surface 123 of a mold body 121 is formed from a cerium oxide-silica sol calcined product.
  • the mold body 121 is configured by a block-shaped body portion 124 and a layer portion 125 adjacent to a cavity 112 .
  • the layer portion 125 has a two-layer structure comprising the initial layer 44 a and the second layer 44 b .
  • the slurry calcined product constituting the body portion 124 may be same as, or different from the cerium oxide-silica sol calcined product constituting the initial layer 44 a and the second layer 44 b .
  • a composition identical to that of the usual mold for example, a calcined product of a slurry composed of a filler comprising at least one selected from zirconia, alumina, silica, mullite, zircon, and yttria as the main component and a binder comprising zirconia sol as the main component
  • a composition identical to that of the usual mold for example, a calcined product of a slurry composed of a filler comprising at least one selected from zirconia, alumina, silica, mullite, zircon, and yttria as the main component and a binder comprising zirconia sol as the main component
  • the cavity surface 123 of the mold body 121 in the shell mold 120 of the present embodiment may also have a one-layer structure or a structure comprising three or more layers.
  • the initial layer 44 a in the solid mold 120 of the present embodiment may be formed from the cerium oxide-silica sol calcined product, and the second layer 44 b may be from the same material as the body portion 124 .
  • FIG. 7 to FIG. 14 A method for manufacturing the mold of the present embodiment will be explained below with reference to FIG. 7 to FIG. 14 .
  • Components identical to those shown in FIG. 1 to FIG. 6 are denoted by identical reference numerals and the explanation of these components is omitted.
  • a wax mold of the same shape and size as a target precision case article (see the below-described FIG. 14 ) is prepared in advance.
  • an initial layer slurry is coated around the wax mold 70 , then the initial layer stucco is coated, and then dried, to form an initial layer slurry film 24 a , as shown in FIG. 8 .
  • a second layer slurry is coated around the initial layer slurry film 24 a , the second layer stucco is coated, and then dried, to form the second layer slurry film 24 b .
  • the initial layer slurry and the second layer slurry are identical.
  • the initial layer slurry film 24 a and the second layer slurry film 24 b constitute a two-layer structure of the initial layer slurry film 24 a.
  • the wax mold 70 provided with the slurry films 24 a , 24 b is disposed in a space 92 of a mold box 91 , and a last layer slurry 93 is injected into the space 92 .
  • the last layer slurry 93 is of a type that cures naturally with the passage of time and may appropriately contain an organic compound (for example, a phenolic resin), a curing agent, and a refractory material. Natural curing of the last layer slurry 93 forms, as shown in FIG. 10 , a block body 103 of the last layer slurry 93 around the wax mold 70 provided with the slurry layers 24 a , 24 b.
  • the wax of the wax mold 70 is then removed using steam and a mold precursor 110 is obtained, as shown in FIG. 11 .
  • the mold precursor 110 has a cavity 112 inside a precursor body 111 .
  • the precursor body 111 is composed of a block body 103 , which is a body portion, and slurry films 24 a , 24 b adjacent to the cavity 112 .
  • a mold (solid mold) 120 of the present embodiment is then obtained, as shown in FIG. 12 , by performing calcination treatment of the mold precursor 110 .
  • the solid mold 120 has the cavity 112 inside the mold body 121 composed of the body portion 124 and the layer portion 125 .
  • the melt 50 of a titanium-aluminum alloy or a titanium alloy is poured into the cavity 112 of the solid mold 120 and casting is performed.
  • the solid mold 120 is thereafter cooled to solidify the melt 50 , and the casting process is completed. As a result, a cast body is formed inside the solid mold 120 .
  • a molded article 140 of titanium-aluminum alloy or titanium alloy is obtained by removing the cast body from the solid mold 120 .
  • the block body 103 of a last layer slurry 93 is formed around the slurry films 24 a , 24 b of a two-layer structure, but this configuration is not limiting.
  • the block body may be directly formed around the wax mold 70 in one manufacturing process.
  • the last layer slurry 93 is identical to the initial layer slurry.
  • the effect obtained with the mold 120 of the present embodiment is identical to that obtained with the mold 40 of the above-described embodiment.
  • the thickness of the ⁇ case layer is thin, which is less than 300 ⁇ m.
  • the thickness of the ⁇ case layer occurring in the surface layer portion was about 280 ⁇ m.
  • the thickness of the ⁇ case layer occurring in the surface layer portion was about 500 ⁇ m. Therefore, it is clear that the thickness of the ⁇ case layer in the titanium alloy molded article 240 is about half that in the titanium alloy molded article 250 .
  • the mold 120 of the present embodiment is suitable as a mold for ultralarge molded articles, decorative articles, artificial teeth, and artificial bones than the molds for precision molded articles. Because the mold 120 has high endurance and small number of layers, it simplifies the manufacturing steps and, therefore, demonstrates excellent cost performance.
US12/065,692 2005-09-07 2006-09-07 Mold and manufacturing method thereof, and molded article using the mold Abandoned US20090169415A1 (en)

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US20100294912A1 (en) * 2006-11-18 2010-11-25 Bentley Motors Limited Ceramic tool having a material applied to the surface
US8708033B2 (en) 2012-08-29 2014-04-29 General Electric Company Calcium titanate containing mold compositions and methods for casting titanium and titanium aluminide alloys
US8858697B2 (en) 2011-10-28 2014-10-14 General Electric Company Mold compositions
US8906292B2 (en) 2012-07-27 2014-12-09 General Electric Company Crucible and facecoat compositions
US8932518B2 (en) 2012-02-29 2015-01-13 General Electric Company Mold and facecoat compositions
US8992824B2 (en) 2012-12-04 2015-03-31 General Electric Company Crucible and extrinsic facecoat compositions
US9011205B2 (en) 2012-02-15 2015-04-21 General Electric Company Titanium aluminide article with improved surface finish
US20150183026A1 (en) * 2013-12-27 2015-07-02 United Technologies Corporation Investment mold having metallic donor element
US20150217366A1 (en) * 2012-10-09 2015-08-06 Mitsubishi Hitachi Power Systems, Ltd. Precision casting mold and method of producing the same
US20150224569A1 (en) * 2012-10-09 2015-08-13 Mitsubishi Hitachi Power Systems, Ltd. Precision casting mold and method of producing the same
US20150266085A1 (en) * 2012-10-09 2015-09-24 Mitsubishi Hitachi Power Systems, Ltd. Precision casting mold and method of producing the same
US20150273571A1 (en) * 2012-10-09 2015-10-01 Mitsubishi Hitachi Power Systems, Ltd. Precision casting mold and method of producing the same
US20150283601A1 (en) * 2012-10-09 2015-10-08 Mitsubishi Hitachi Power Systems, Ltd. Precision casting mold and method of producing the same
US9192983B2 (en) 2013-11-26 2015-11-24 General Electric Company Silicon carbide-containing mold and facecoat compositions and methods for casting titanium and titanium aluminide alloys
US9511417B2 (en) 2013-11-26 2016-12-06 General Electric Company Silicon carbide-containing mold and facecoat compositions and methods for casting titanium and titanium aluminide alloys
US9592548B2 (en) 2013-01-29 2017-03-14 General Electric Company Calcium hexaluminate-containing mold and facecoat compositions and methods for casting titanium and titanium aluminide alloys
US10391547B2 (en) 2014-06-04 2019-08-27 General Electric Company Casting mold of grading with silicon carbide

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US20100294912A1 (en) * 2006-11-18 2010-11-25 Bentley Motors Limited Ceramic tool having a material applied to the surface
US8858697B2 (en) 2011-10-28 2014-10-14 General Electric Company Mold compositions
US9011205B2 (en) 2012-02-15 2015-04-21 General Electric Company Titanium aluminide article with improved surface finish
US8932518B2 (en) 2012-02-29 2015-01-13 General Electric Company Mold and facecoat compositions
US9802243B2 (en) 2012-02-29 2017-10-31 General Electric Company Methods for casting titanium and titanium aluminide alloys
US8906292B2 (en) 2012-07-27 2014-12-09 General Electric Company Crucible and facecoat compositions
US8708033B2 (en) 2012-08-29 2014-04-29 General Electric Company Calcium titanate containing mold compositions and methods for casting titanium and titanium aluminide alloys
US20150217366A1 (en) * 2012-10-09 2015-08-06 Mitsubishi Hitachi Power Systems, Ltd. Precision casting mold and method of producing the same
US20150224569A1 (en) * 2012-10-09 2015-08-13 Mitsubishi Hitachi Power Systems, Ltd. Precision casting mold and method of producing the same
US20150266085A1 (en) * 2012-10-09 2015-09-24 Mitsubishi Hitachi Power Systems, Ltd. Precision casting mold and method of producing the same
US20150273571A1 (en) * 2012-10-09 2015-10-01 Mitsubishi Hitachi Power Systems, Ltd. Precision casting mold and method of producing the same
US20150283601A1 (en) * 2012-10-09 2015-10-08 Mitsubishi Hitachi Power Systems, Ltd. Precision casting mold and method of producing the same
US9803923B2 (en) 2012-12-04 2017-10-31 General Electric Company Crucible and extrinsic facecoat compositions and methods for melting titanium and titanium aluminide alloys
US8992824B2 (en) 2012-12-04 2015-03-31 General Electric Company Crucible and extrinsic facecoat compositions
US9592548B2 (en) 2013-01-29 2017-03-14 General Electric Company Calcium hexaluminate-containing mold and facecoat compositions and methods for casting titanium and titanium aluminide alloys
US9192983B2 (en) 2013-11-26 2015-11-24 General Electric Company Silicon carbide-containing mold and facecoat compositions and methods for casting titanium and titanium aluminide alloys
US9511417B2 (en) 2013-11-26 2016-12-06 General Electric Company Silicon carbide-containing mold and facecoat compositions and methods for casting titanium and titanium aluminide alloys
US20150183026A1 (en) * 2013-12-27 2015-07-02 United Technologies Corporation Investment mold having metallic donor element
US10391547B2 (en) 2014-06-04 2019-08-27 General Electric Company Casting mold of grading with silicon carbide

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JP4451907B2 (ja) 2010-04-14
US20100147485A1 (en) 2010-06-17
WO2007029785A1 (ja) 2007-03-15
EP1938918A1 (en) 2008-07-02
JPWO2007029785A1 (ja) 2009-03-19
EP1938918B1 (en) 2016-03-16
KR101364563B1 (ko) 2014-02-18
KR20080046169A (ko) 2008-05-26

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