US20110203760A1 - Method for making a mold for casting highly reactive molten masses - Google Patents

Method for making a mold for casting highly reactive molten masses Download PDF

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Publication number
US20110203760A1
US20110203760A1 US12/998,168 US99816809A US2011203760A1 US 20110203760 A1 US20110203760 A1 US 20110203760A1 US 99816809 A US99816809 A US 99816809A US 2011203760 A1 US2011203760 A1 US 2011203760A1
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US
United States
Prior art keywords
layer
slicker
dry mass
making
hydraulic binder
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Abandoned
Application number
US12/998,168
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English (en)
Inventor
Manfred Renkel
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G4T GmbH
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G4T GmbH
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Filing date
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Assigned to G4T GMBH reassignment G4T GMBH ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: RENKEL, MANFRED
Publication of US20110203760A1 publication Critical patent/US20110203760A1/en
Abandoned legal-status Critical Current

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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
    • B22C9/04—Use of lost patterns
    • 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
    • B22C3/00—Selection of compositions for coating the surfaces of moulds, cores, or patterns

Definitions

  • the invention relates to a method for making a mold for casting highly reactive molten masses, in particular forcasting titanium, titanium alloys or intermetallic titanium aluminides, as defined by the preamble of claim 1 .
  • a slicker contains yttrium oxide, magnesium oxide and calcium oxide for the making of a contact layer or face-coat layer. Together with the water of the slicker, the magnesium oxide causes an exothermal reaction during which water evaporates and the drying time of the contact layer made from the slicker is reduced. None is known from this document about the amount or the amount relationships of the oxides used.
  • the object of this invention is to eliminate the disadvantages as per prior art.
  • a method for making a mold for casting highly reactive molten masses is to be specified which can be performed as simply, reproducibly and quickly as possible.
  • a first dry mass for making the first slicker contains at least 75 wt. % of Y 2 O 3 and as an additional solid component at least 1.0 to 25 wt. % of a hydraulic binder.
  • a “hydraulic binder” is understood to mean a mixture of substances which hydrates with water. The hydration products formed by this cause the solid components contained in the slicker to harden.
  • a particularly fast hardening of the first slicker can be achieved with the suggested composition.
  • the first dry mass contains less than 95 wt. % of Y 2 O 3 , preferably less than 90 wt. %.
  • the relatively expensive Y 2 O 3 component which is required for the stability against a corrosive attack by highly reactive molten masses can be reduced by adding a hydraulic binder without reducing the resistance of the contact layer to the corrosive effect of highly reactive molten masses.
  • the content of Y 2 O 3 in the first dry mass can be reduced to 80 or 85 wt. %.
  • Part of the Y 2 O 3 , 5 to 10 wt. % for example, can be replaced by TiO 2 .
  • the content of the hydraulic binder is advantageously between 8 and 16 wt. %.
  • the first slicker can be applied with an injection method to the mold core using the method in accordance with the invention. This permits the making of a particularly smooth and thin contact layer as well as a particularly efficient performance of the method.
  • the grain band of the first powder is between 0 and 50 ⁇ m and advantageously has a medium grain size (d 50 ) in the range from 8 to 20 ⁇ m. It has been shown that a slicker with the suggested grain size distribution can be processed particularly well with the injection method on the one hand, and on the other hand, a high surface quality of the contact layer can be achieved with this.
  • the second Y 2 O 3 powder can have a medium grain size (d 50 ) in the range from 130 to 200 ⁇ m.
  • the suggested medium grain size of the second Y 2 O 3 powder contributes to good pourability and . thus makes sanding the contact layer easier.
  • the hydraulic binder preferably contains CaO*Al 2 O 3 .
  • Such a calcium aluminate cement usefully contains 60 to 80 wt. % of Al 2 O 3 , preferably approximately 70 wt. % of Al 2 O 3 .
  • a contact layer made by using the suggested hydraulic binder exhibits an excellent hardness.
  • the first dry mass usefully only contains unavoidable impurities of MgO. A particularly good resistance to highly reactive molten masses, in particularly to titanium aluminide molten masses, can be achieved with this.
  • a coating layer surrounding the layer sequence of contact layer and first sanding layer or the plurality of layer sequences can be established.
  • the coating layer can contain MgO as an essential component.
  • a second dry mass for making the coating layer can contain a hydraulic binder, preferably calcium aluminate cement.
  • the latter contains 60 to 80 wt. % of Al 2 O 3 , preferably approximately 70 wt. % of Al 2 O 3 .
  • a second dry mass usefully contains at least 40 wt. % of MgO, preferably 60 to 80 wt. %, as well as at least 20 wt. % of the hydraulic binder.
  • the second dry mass can contain one or more of the following oxides: Fe 2 O 3 , SiO 2 , CaO, Al 2 O 3 .
  • the coating layer is essentially used for the mechanical stabilization of the contact layer. It can have a significantly greater layer thickness than the contact layer.
  • the intermediate layer can be made by a second slicker applied using the injection or dipping method.
  • the second slicker can contain a first MgO powder as the essential solid component.
  • the second slicker can have a hydraulic binder, preferably a calcium aluminate cement (CaO*Al 2 O 3 ) with 60 to 80 wt. % of Al 2 O 3 , preferably approximately 70 wt. % of Al 2 O 3 .
  • a third dry mass for making the second slicker can contain at least 50 wt. % of MgO, preferably 60 to 70 wt. % and at least 20 wt. % of the hydraulic binder.
  • the second sanding layer is usefully made by applying a second MgO powder onto the second slicker layer.
  • intermediate layer sequences which are formed respectively from an intermediate layer and a second sanding layer can be applied in succession onto the layer sequence made of the contact and first sanding layer.
  • the first MgO powder can have a smaller medium grain size than the second MgO powder.
  • first and/or the third dry mass/masses and/or the sanding layer/layers can contain at least one of the following oxides: CeO 2 , La 2 O 3 , Gd 2 O 3 , Nd 2 O 3 , Ti 0 2 .
  • the addition of other oxides of the rare earths is also possible.
  • the thus established intermediate layer sequence contributes to an improved thermo shock resistance of the mold. Since the intermediate layers also contain a hydraulic binder, they can also be made quickly and efficiently, particularly using the injection method.
  • a moisture content of the contact and/or the. intermediate layer can be reduced via infrared radiation to a specified value after their application.
  • the specified value can be in the range from 10 to 60% of residual moisture, preferably less than 20% and more than 5% of residual moisture.
  • the fraction of hydraulic binder in the first dry mass is less than in the second or third dry mass.
  • the fraction of the hydraulic binder in the second and/or third dry mass is advantageously at least 2 wt. %, preferably at least 5 wt. % greater than in the first dry mass.
  • the first and/or second slicker has/have a viscosity of not more than 1000 mPas, preferably between 450 and 750 mPas. Slickers with such a viscosity can be processed particularly well using the injection method.
  • the mold core is removed by melting or burning out the material creating the mold core after the coating layer is made.
  • the material is usefully wax or similar.
  • a green body created after removing the mold core is usefully sintered at a sintering temperature of more than 800° C. and less than 1200° C. Using a hydraulic binder for making the mold as suggested by the invention thus also contributes to a significant reduction in the sintering temperatures.
  • a contact layer 1 contains 85 wt. % of Y 2 O 3 and 15 wt. % of hydration products of the calcium aluminate cement, for example. Aside from unavoidable impurities, it is usefully free of MgO.
  • Reference sign 2 designates a first sanding layer which essentially consists of a further Y 2 O 3 powder having a medium grain size of approximately 150 ⁇ m. Aside from unavoidable impurities, the first sanding layer 2 is also usefully free of MgO.
  • the contact layer 1 and the first sanding layer 2 form a layer sequence A.
  • An intermediate layer 3 is applied onto the first sanding layer 2 which intermediate layer 3 contains MgO as the essential component which in turn is set by the reactive product of a calcium aluminate cement.
  • Reference sign 4 designates a second sanding layer which is made from an MgO powder.
  • An intermediate layer sequence made of alternating layers of intermediate layer 3 and second sanding layer 4 is designated by the reference sign B.
  • the intermediate layer sequence B is lined in the back with a coating layer 5 which contains MgO as the essential solid component which in turn is set by a hydraulic binder, preferably calcium aluminate cement.
  • the layer sequence A can also be created from a sequence of several contact layers 1 as well as first sanding layers 2 in alternating sequence.
  • a first slicker is made first whose first dry mass contains 80 to 90 wt. % of a first Y 2 O 3 powder.
  • the medium grain size d 50 of the first Y 2 O 3 powder is usefully 10 to 15 ⁇ m.
  • the modal value is advantageously 15 to 25 ⁇ m.
  • the grain band is usefully in the range between 0 and 50 ⁇ m.
  • the first dry mass contains 10 to 20 wt. %, preferably 8 to 17 wt % of a calcium aluminate cement. Adding a suitable amount of water creates a first slicker having a viscosity in the range from 400 to 700 mPas.
  • the first slicker is injected using the injection method onto a mold core made, for example, of wax. Then the contact layer 1 made from the first slicker is sanded with a first sanding layer 2 .
  • the first sanding layer 2 consists of a second Y 2 O 3 powder which has a medium grain size in the range from 170 to 200 ⁇ m and usefully contains only unavoidable impurities.
  • the thus created layer sequence A is then dried for a period of approximately 90 to 180 minutes or a suitable residual moisture of 10 to 30% is set.
  • the previously mentioned procedure of making the contact layer 1 as well as the first sanding layer 2 can be repeated multiple times, three to five times, for example.
  • the layer sequence A can also be concluded by a contact layer 1 instead of the first sanding layer 2 . It can also be that a first sanding layer which concludes the layer sequence A is essentially made of an MgO powder.
  • This MgO powder can be made like the second Y 2 O 3 powder regarding its grain size distribution as well as its medium grain size.
  • a second slicker is made to make one or more intermediate layers 3 of the intermediate layer sequence B.
  • a second dry mass for making the second slicker contains, for example, 65 to 80 wt. %, preferably 65 to 70 wt. % of MgO as well as 20 to 35 wt. %, preferably 30 to 35 wt. % of a calcium aluminate cement. Adding a suitable amount of water makes a second slicker whose viscosity is usefully set so that it enables a coating using the conventional dipping method.
  • the layer sequence A applied onto the mold core is coated with the second slicker using the dipping method.
  • the second sanding layer 4 is applied which is essentially created from an MgO powder having . a grain size in the range from 0.1 to 2.0 mm.
  • the thus created intermediate layer sequence B is dried for a period of 15 to 45 minutes or a suitable residual moisture of 10 to 30% is set. Additional intermediate 3 and second sanding layers 4 can then be applied in the same way. Finally, the intermediate layer sequence B can be dried for a period of 30 to 100 minutes.
  • the coating layer 5 60 to 80 wt. %, preferably 70 to 80 wt. % of MgO, 20 to 40 wt. %, preferably 20 to 30 wt. % of calcium aluminate cement as well as water and auxiliary substances are used to make a still flowable mass.
  • the coated mold core is then placed in a mold and surrounded with the flowable mass. The mold is removed after the flowable mass has dried. The mold core is removed by increasing the temperature. Then the thus created green body of the mold is sintered at a temperature in the range from 1000 to 1200° C., preferably in the range from 1100 to 1200° C.
  • a first dry mass for making the first slicker contains 60 to 70 wt. % of Y 2 O 3 and 10 to 20 wt. % of CeO 2 .
  • the grain band of the mixture is between 0 and 50 ⁇ m.
  • the first dry mass contains 10 to 20 wt. % of the calcium aluminate cement.
  • the first dry mass is mixed with water so that a first slicker having a viscosity in the range from 300 to 600 mPas is created.
  • the drying of the layer sequence A as well as the intermediate layer sequence B can also be supported with infrared radiation.
  • the coated mold core can be led through a drying chamber in which the air temperature is in the range from 30 to 60° C.
  • first and/or second slicker can also contain conventional auxiliary substances, in particular the organic auxiliary substances in the usual amounts.
US12/998,168 2008-09-25 2009-09-24 Method for making a mold for casting highly reactive molten masses Abandoned US20110203760A1 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
DE102008042376.9 2008-09-25
DE102008042376A DE102008042376A1 (de) 2008-09-25 2008-09-25 Verfahren zur Herstellung einer Gussform zum Vergießen hochreaktiver Schmelzen
PCT/EP2009/062355 WO2010034762A2 (de) 2008-09-25 2009-09-24 Verfahren zur herstellung einer gussform zum vergiessen hochreaktiver schmelzen

Publications (1)

Publication Number Publication Date
US20110203760A1 true US20110203760A1 (en) 2011-08-25

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US12/998,168 Abandoned US20110203760A1 (en) 2008-09-25 2009-09-24 Method for making a mold for casting highly reactive molten masses

Country Status (5)

Country Link
US (1) US20110203760A1 (de)
EP (1) EP2337645B1 (de)
JP (1) JP2012503552A (de)
DE (1) DE102008042376A1 (de)
WO (1) WO2010034762A2 (de)

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20150144286A1 (en) * 2013-11-26 2015-05-28 General Electric Company Silicon carbide-containing mold and facecoat compositions and methods for casting titanium and titanium aluminide alloys
CN109063322A (zh) * 2018-07-27 2018-12-21 哈尔滨理工大学 一种铸件缩松缺陷数值预测的方法
EP3560627A1 (de) * 2018-04-24 2019-10-30 Ceranovis GmbH Trennschicht, schlichte zu ihrer herstellung, mit der trennschicht beschichtete gegenstände und verfahren zur metallverarbeitung

Families Citing this family (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US8579013B2 (en) * 2011-09-30 2013-11-12 General Electric Company Casting mold composition with improved detectability for inclusions and method of casting
DE102016124322A1 (de) 2016-12-14 2018-06-14 Manfred Renkel Verfahren zur Herstellung einer Gussform zum Vergießen einer hochreaktiven Schmelze
DE102016124321A1 (de) 2016-12-14 2018-03-01 Manfred Renkel Verfahren zur Herstellung einer Gussform zum Vergießen einer hochreaktiven Schmelze

Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3994346A (en) * 1972-11-24 1976-11-30 Rem Metals Corporation Investment shell mold, for use in casting of reacting and refractory metals
US4557316A (en) * 1983-07-01 1985-12-10 Agency Of Industrial Science & Technology Method for manufacture of investment shell mold suitable for casting grain-oriented super alloy
US5868194A (en) * 1996-01-31 1999-02-09 Rolls-Royce Plc Method of investment casting and a method of making an investment casting mould
US5944088A (en) * 1987-01-28 1999-08-31 Remet Corporation Ceramic shell molds and cores for casting of reactive metals
US20050092459A1 (en) * 2003-10-30 2005-05-05 Wisys Technology Foundation, Inc. Investment casting slurry composition and method of use
US20060086480A1 (en) * 2004-10-05 2006-04-27 Michael Kugelgen Method and system for producing a shell mould, in particular for investment casting

Family Cites Families (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4063954A (en) * 1974-03-05 1977-12-20 Rem Metals Corporation Fluoride-type with heat sink for casting molten reactive and refractory metals
EP0093212B1 (de) * 1982-05-04 1986-08-27 Remet Corporation Feuerfestes Material
US4703806A (en) * 1986-07-11 1987-11-03 Howmet Turbine Components Corporation Ceramic shell mold facecoat and core coating systems for investment casting of reactive metals
DE10346953A1 (de) 2003-10-09 2005-05-04 Mtu Aero Engines Gmbh Werkzeug zum Herstellen von Gussbauteilen, Verfahren zum Herstellen des Werkzeugs und Verfahren zum Herstellen von Gussbauteilen

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3994346A (en) * 1972-11-24 1976-11-30 Rem Metals Corporation Investment shell mold, for use in casting of reacting and refractory metals
US4557316A (en) * 1983-07-01 1985-12-10 Agency Of Industrial Science & Technology Method for manufacture of investment shell mold suitable for casting grain-oriented super alloy
US5944088A (en) * 1987-01-28 1999-08-31 Remet Corporation Ceramic shell molds and cores for casting of reactive metals
US5868194A (en) * 1996-01-31 1999-02-09 Rolls-Royce Plc Method of investment casting and a method of making an investment casting mould
US20050092459A1 (en) * 2003-10-30 2005-05-05 Wisys Technology Foundation, Inc. Investment casting slurry composition and method of use
US20060086480A1 (en) * 2004-10-05 2006-04-27 Michael Kugelgen Method and system for producing a shell mould, in particular for investment casting

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20150144286A1 (en) * 2013-11-26 2015-05-28 General Electric Company Silicon carbide-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
EP3560627A1 (de) * 2018-04-24 2019-10-30 Ceranovis GmbH Trennschicht, schlichte zu ihrer herstellung, mit der trennschicht beschichtete gegenstände und verfahren zur metallverarbeitung
CN109063322A (zh) * 2018-07-27 2018-12-21 哈尔滨理工大学 一种铸件缩松缺陷数值预测的方法

Also Published As

Publication number Publication date
EP2337645B1 (de) 2020-04-22
JP2012503552A (ja) 2012-02-09
WO2010034762A3 (de) 2010-08-19
WO2010034762A2 (de) 2010-04-01
EP2337645A2 (de) 2011-06-29
DE102008042376A1 (de) 2010-04-08

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