US20120111525A1 - High temperature die casting apparatus and method therefor - Google Patents
High temperature die casting apparatus and method therefor Download PDFInfo
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- US20120111525A1 US20120111525A1 US12/940,362 US94036210A US2012111525A1 US 20120111525 A1 US20120111525 A1 US 20120111525A1 US 94036210 A US94036210 A US 94036210A US 2012111525 A1 US2012111525 A1 US 2012111525A1
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- United States
- Prior art keywords
- die casting
- high temperature
- barrier coating
- recited
- carbide
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Links
- 238000004512 die casting Methods 0.000 title claims abstract description 87
- 238000000034 method Methods 0.000 title claims description 10
- 239000000463 material Substances 0.000 claims abstract description 43
- 239000011248 coating agent Substances 0.000 claims abstract description 42
- 238000000576 coating method Methods 0.000 claims abstract description 42
- 230000004888 barrier function Effects 0.000 claims abstract description 39
- 239000000758 substrate Substances 0.000 claims abstract description 21
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 claims description 23
- MCMNRKCIXSYSNV-UHFFFAOYSA-N Zirconium dioxide Chemical compound O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 claims description 12
- CMIHHWBVHJVIGI-UHFFFAOYSA-N gadolinium(iii) oxide Chemical compound [O-2].[O-2].[O-2].[Gd+3].[Gd+3] CMIHHWBVHJVIGI-UHFFFAOYSA-N 0.000 claims description 10
- 229910052759 nickel Inorganic materials 0.000 claims description 10
- 229910000990 Ni alloy Inorganic materials 0.000 claims description 7
- 229910000601 superalloy Inorganic materials 0.000 claims description 7
- 239000003870 refractory metal Substances 0.000 claims description 6
- 229910052727 yttrium Inorganic materials 0.000 claims description 6
- 239000011651 chromium Substances 0.000 claims description 5
- 229910017052 cobalt Inorganic materials 0.000 claims description 5
- 239000010941 cobalt Substances 0.000 claims description 5
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 claims description 5
- 229910002078 fully stabilized zirconia Inorganic materials 0.000 claims description 5
- 239000000203 mixture Substances 0.000 claims description 5
- 229910002077 partially stabilized zirconia Inorganic materials 0.000 claims description 5
- BASFCYQUMIYNBI-UHFFFAOYSA-N platinum Chemical compound [Pt] BASFCYQUMIYNBI-UHFFFAOYSA-N 0.000 claims description 5
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 claims description 4
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- 239000011733 molybdenum Substances 0.000 claims description 4
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- 229910052710 silicon Inorganic materials 0.000 claims description 4
- 239000010703 silicon Substances 0.000 claims description 4
- HQVNEWCFYHHQES-UHFFFAOYSA-N silicon nitride Chemical compound N12[Si]34N5[Si]62N3[Si]51N64 HQVNEWCFYHHQES-UHFFFAOYSA-N 0.000 claims description 4
- WFKWXMTUELFFGS-UHFFFAOYSA-N tungsten Chemical compound [W] WFKWXMTUELFFGS-UHFFFAOYSA-N 0.000 claims description 4
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- 239000010937 tungsten Substances 0.000 claims description 4
- VWQVUPCCIRVNHF-UHFFFAOYSA-N yttrium atom Chemical compound [Y] VWQVUPCCIRVNHF-UHFFFAOYSA-N 0.000 claims description 4
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- 239000012535 impurity Substances 0.000 claims description 3
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- 229910010271 silicon carbide Inorganic materials 0.000 claims description 3
- 229910052715 tantalum Inorganic materials 0.000 claims description 3
- GUVRBAGPIYLISA-UHFFFAOYSA-N tantalum atom Chemical compound [Ta] GUVRBAGPIYLISA-UHFFFAOYSA-N 0.000 claims description 3
- MTPVUVINMAGMJL-UHFFFAOYSA-N trimethyl(1,1,2,2,2-pentafluoroethyl)silane Chemical compound C[Si](C)(C)C(F)(F)C(F)(F)F MTPVUVINMAGMJL-UHFFFAOYSA-N 0.000 claims description 3
- UONOETXJSWQNOL-UHFFFAOYSA-N tungsten carbide Chemical compound [W+]#[C-] UONOETXJSWQNOL-UHFFFAOYSA-N 0.000 claims description 3
- 229910052582 BN Inorganic materials 0.000 claims description 2
- PZNSFCLAULLKQX-UHFFFAOYSA-N Boron nitride Chemical compound N#B PZNSFCLAULLKQX-UHFFFAOYSA-N 0.000 claims description 2
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- 229910052691 Erbium Inorganic materials 0.000 claims description 2
- 229910052693 Europium Inorganic materials 0.000 claims description 2
- 241000588731 Hafnia Species 0.000 claims description 2
- 229910052689 Holmium Inorganic materials 0.000 claims description 2
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- KJTLSVCANCCWHF-UHFFFAOYSA-N Ruthenium Chemical compound [Ru] KJTLSVCANCCWHF-UHFFFAOYSA-N 0.000 claims description 2
- 229910052772 Samarium Inorganic materials 0.000 claims description 2
- 229910052776 Thorium Inorganic materials 0.000 claims description 2
- 229910052775 Thulium Inorganic materials 0.000 claims description 2
- 229910052769 Ytterbium Inorganic materials 0.000 claims description 2
- CETPSERCERDGAM-UHFFFAOYSA-N ceric oxide Chemical compound O=[Ce]=O CETPSERCERDGAM-UHFFFAOYSA-N 0.000 claims description 2
- 229910000422 cerium(IV) oxide Inorganic materials 0.000 claims description 2
- PMHQVHHXPFUNSP-UHFFFAOYSA-M copper(1+);methylsulfanylmethane;bromide Chemical compound Br[Cu].CSC PMHQVHHXPFUNSP-UHFFFAOYSA-M 0.000 claims description 2
- CJNBYAVZURUTKZ-UHFFFAOYSA-N hafnium(IV) oxide Inorganic materials O=[Hf]=O CJNBYAVZURUTKZ-UHFFFAOYSA-N 0.000 claims description 2
- 229910052738 indium Inorganic materials 0.000 claims description 2
- 229910052741 iridium Inorganic materials 0.000 claims description 2
- GKOZUEZYRPOHIO-UHFFFAOYSA-N iridium atom Chemical compound [Ir] GKOZUEZYRPOHIO-UHFFFAOYSA-N 0.000 claims description 2
- 229910052746 lanthanum Inorganic materials 0.000 claims description 2
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- MHOVAHRLVXNVSD-UHFFFAOYSA-N rhodium atom Chemical compound [Rh] MHOVAHRLVXNVSD-UHFFFAOYSA-N 0.000 claims description 2
- 229910052707 ruthenium Inorganic materials 0.000 claims description 2
- 229910052706 scandium Inorganic materials 0.000 claims description 2
- -1 silicon-aluminum oxy nitride Chemical class 0.000 claims description 2
- QIJNJJZPYXGIQM-UHFFFAOYSA-N 1lambda4,2lambda4-dimolybdacyclopropa-1,2,3-triene Chemical compound [Mo]=C=[Mo] QIJNJJZPYXGIQM-UHFFFAOYSA-N 0.000 claims 1
- 229910039444 MoC Inorganic materials 0.000 claims 1
- UNASZPQZIFZUSI-UHFFFAOYSA-N methylidyneniobium Chemical compound [Nb]#C UNASZPQZIFZUSI-UHFFFAOYSA-N 0.000 claims 1
- NFFIWVVINABMKP-UHFFFAOYSA-N methylidynetantalum Chemical compound [Ta]#C NFFIWVVINABMKP-UHFFFAOYSA-N 0.000 claims 1
- 229910003468 tantalcarbide Inorganic materials 0.000 claims 1
- 238000002844 melting Methods 0.000 description 16
- 230000008018 melting Effects 0.000 description 16
- 229910052751 metal Inorganic materials 0.000 description 11
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- 230000008901 benefit Effects 0.000 description 2
- 239000007789 gas Substances 0.000 description 2
- 229910052758 niobium Inorganic materials 0.000 description 2
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- GUCVJGMIXFAOAE-UHFFFAOYSA-N niobium atom Chemical compound [Nb] GUCVJGMIXFAOAE-UHFFFAOYSA-N 0.000 description 2
- 150000004767 nitrides Chemical class 0.000 description 2
- 229910000838 Al alloy Inorganic materials 0.000 description 1
- 229910017150 AlTi Inorganic materials 0.000 description 1
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- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 1
- 229910000640 Fe alloy Inorganic materials 0.000 description 1
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 1
- 229910001069 Ti alloy Inorganic materials 0.000 description 1
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 description 1
- QCWXUUIWCKQGHC-UHFFFAOYSA-N Zirconium Chemical compound [Zr] QCWXUUIWCKQGHC-UHFFFAOYSA-N 0.000 description 1
- 229910052786 argon Inorganic materials 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- WUKWITHWXAAZEY-UHFFFAOYSA-L calcium difluoride Chemical compound [F-].[F-].[Ca+2] WUKWITHWXAAZEY-UHFFFAOYSA-L 0.000 description 1
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- 239000010436 fluorite Substances 0.000 description 1
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- 238000009966 trimming Methods 0.000 description 1
- 229910052726 zirconium Inorganic materials 0.000 description 1
Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
- B22D17/20—Accessories: Details
- B22D17/22—Dies; Die plates; Die supports; Cooling equipment for dies; Accessories for loosening and ejecting castings from dies
- B22D17/2209—Selection of die materials
Definitions
- This disclosure relates to die casting and, more specifically, a die casting system that has the ability to operate at high temperatures.
- die casting is a process that includes moving molten metal into a die cavity to form a desired shape.
- the process typically includes transporting the molten metal into the die cavity, holding the metal in the cavity for a period of time until the casting solidifies, removing the casting from the die cavity, and trimming the casting to remove any scrap.
- a disclosed high temperature die casting system includes a die casting tool that has dies that are adapted for forming a component. Due to the nature of the process, the die casting tool is operable to heat and maintain a temperature of the dies above 500° F./260° C. At least a portion of the die casting tool that is exposed for contact with molten die casting material has a substrate and barrier coating on the substrate to protect from the molten die casting material.
- a high temperature die casting system in another aspect, includes a die casting tool having a substrate and a barrier coating on the substrate.
- the barrier coating is a material selected from partially or fully stabilized zirconia, titanium nitride, tungsten carbide, silicon carbide, silicon nitride, titanium carbide, silicon-oxygen-aluminum-nitrogen, hafnium carbide, zirconium carbide, and combinations thereof.
- An exemplary method for a high temperature die casting system includes maintaining a die casting tool having dies that are adapted for forming a component at a temperature above 500° F./260° C., and using a barrier coating on at least a portion of the die casting tool that is exposed for contact with molten die casting material to protect the underlying substrate of the die casting tool from contact with the molten die casting material.
- FIG. 1 illustrates an example die casting system
- FIG. 2 illustrates an example die casting tool having a barrier coating.
- FIG. 3 illustrates another example die casting tool having a barrier coating and a bond coat.
- FIG. 1 illustrates a die casting system 10 including a reusable die 12 having a plurality of die elements 14 , 16 that function to cast a component 15 .
- the component 15 could include aeronautical components, such as a gas turbine engine blade or vane, or non-aeronautical components.
- two die elements 14 , 16 are depicted by FIG. 1 , it should be understood that the die 12 could include more or fewer die elements, as well as other parts and other configurations.
- the die 12 is assembled by positioning the die elements 14 , 16 together and holding the die elements 14 , 16 at a desired position via a mechanism 18 .
- the mechanism 18 could include a clamping mechanism of appropriate hydraulic, pneumatic, electromechanical, and/or other configurations.
- the mechanism 18 also separates the die elements 14 , 16 subsequent to casting.
- the die elements 14 , 16 include internal surfaces that cooperate to define a die cavity 20 .
- the die elements 14 , 16 may additionally include one or more heating elements 17 for heating and maintaining the die cavity 20 at a desired temperature above 500° F./260° C.
- the heating elements may heat the die elements 14 , 16 up to 500° F./260° C. during initial start-up of the die elements 14 , 16 , maintain the desired temperature during operation of the die elements 14 , 16 , and maintain the desired temperature during thermal cycling as components are produced in the die casting system 10 .
- the heating elements 17 may be resistance heaters, induction heaters, a recirculating thermal medium, such as, but not limited to hot oil, or combinations of different kinds of heaters that are operable to heat the die cavity 20 to the desired temperature and then maintain that temperature (e.g., via non-application of heat or in combination with a cooling element).
- a recirculating thermal medium such as, but not limited to hot oil
- Traditional casting dies are not commonly equipped to specifically heat the cavity and may be present in the system for the purpose of removing excess heat from the die.
- the elevated temperature of die elements 14 , 16 serves to reduce the temperature differential between the die elements and the molten die casting material to reduce heat checking.
- a shot tube 24 is in fluid communication with the die cavity 20 via one or more ports 26 that extend into the die element 14 , the die element 16 or both.
- a shot tube plunger 28 is received within the shot tube 24 and is moveable between a retracted and injected position (in the direction of arrow A) within the shot tube 24 by a mechanism 30 .
- a shaft 31 extends between the mechanism 30 and the shot tube plunger 28 .
- the mechanism 30 could include a hydraulic assembly or other suitable system, including, but not limited to, pneumatic, electromechanical, hydraulic or any combination of systems.
- the shot tube 24 is positioned to receive a charge of material from a melting unit 32 , such as a crucible, for example.
- the melting unit 32 may utilize any known technique for melting an ingot of metallic material to prepare molten metal for delivery to the shot tube 24 , such as will be further discussed below.
- the charge of material is melted into molten metal by the melting unit 32 at a location that is separate from the shot tube 24 and the die 12 .
- other melting configurations are contemplated as within the scope of this disclosure.
- the example melting unit 32 is positioned in relative close proximity to the die casting system 10 to reduce the transfer distance of the charge of material between the melting unit 32 and the die casting system 10 .
- Materials used to die cast a component 15 with the die casting system 10 include, but are not limited to, nickel-based super alloys, cobalt-based super alloys, titanium alloys, high temperature aluminum alloys, copper-based alloys, iron alloys, molybdenum, tungsten, niobium or other refractory metals. This disclosure is not limited to the disclosed alloys, and other high melting temperature materials may be utilized to die cast a component 15 . As used in this disclosure, the term “high melting temperature material” is intended to include materials having a melting temperature of approximately 1500° F./815° C. and higher.
- the charge of material is transferred from the melting unit 32 to the die casting system 10 .
- the charge of material may be poured into a pour hole 33 of the shot tube 24 .
- a sufficient amount of molten metal is poured into the shot tube to fill the die cavity 20 .
- the shot tube plunger 28 is actuated to inject the charge of material under pressure from the shot tube 24 into the die cavity 20 to cast the component 15 .
- the die casting system 10 could be configured to cast multiple components in a single shot.
- the die casting system 10 can be positioned within a vacuum chamber 34 that includes a vacuum source 35 .
- a vacuum is applied in the vacuum chamber 34 via the vacuum source 35 to render a vacuum die casting process.
- the vacuum chamber 34 provides a non-reactive environment for the die casting system 10 that reduces reaction, contamination or other conditions that could detrimentally affect the quality of the die cast component, such as gas entrapment or the formation of oxides or nitrides within the die cast component that can occur from exposure to atmospheric gasses.
- the vacuum chamber 34 is maintained at a pressure between 1 ⁇ 10 ⁇ 3 Torr and 1 ⁇ 10 ⁇ 4 Torr, although other pressures are contemplated.
- each of the melting unit 32 , the shot tube 24 and the die 12 are positioned within the vacuum chamber 34 during the die casting process such that the melting, injecting and solidifying of the high melting temperature material are all performed under vacuum.
- the chamber 34 is backfilled with an inert gas, such as Argon, for example.
- the example die casting system 10 of FIG. 1 is illustrative only and could include more or fewer sections, parts and/or components. This disclosure extends to all forms of die casting, including but not limited to, horizontal, inclined, or vertical die casting systems and other die casting configurations.
- the die casting system 10 utilizes a barrier coating 40 that protects the die casting system 10 from the effects of the high temperature molten die casting material.
- the die casting system 10 includes the barrier coating 40 on at least a portion of the tool surfaces that are exposed for contact with the molten die casting material, to alleviate heat checking or other influences of the high temperature die casting material.
- the components of the die casting system 10 that has a surface that contacts the molten metal is considered to be a die casting tool or component.
- the surfaces of the die cavity 20 , shot tube 24 , shot tube plunger 28 , melting unit 32 , pour hole 33 , and any runners or gates may include the barrier coating 40 .
- FIG. 2 illustrates a selected portion of one such area that includes the barrier coating 40 on a substrate 42 of a given die casting tool.
- the barrier coating 40 is deposited directly onto the surface of the substrate 42 .
- the substrate 42 may be any suitable material for the given component.
- the substrate 42 may be a superalloy, such as a nickel and/or cobalt alloy. It is to be understood, however, that the material of the substrate 42 is not limited to any particular composition and one of ordinary skill in the art would be able to recognize suitable materials to meet their particular needs.
- the barrier coating 40 forms a thermal barrier between the molten die casting material and the underlying substrate 42 .
- the material of the barrier coating 40 has a relatively high thermal resistance.
- the barrier coating 40 may be a ceramic material, such as an oxide, a nitride, a carbide, a zirconia material, a gadolinia material or combinations thereof.
- the oxide may be a combination of several different oxides, including at least one oxide and the balance comprising a first oxide.
- the first oxide may be selected from the group consisting of zirconia, ceria, and hafnia.
- the at least one oxide may have a formula A 2 O 3 , where A is selected from the group consisting of La, Pr, Nd, Sm, Eu, Th, In, Sc, Y, Dy, Ho, Er, Tm, Yb, Lu, and mixtures thereof.
- the carbide may be a refractory metal carbide, such as a carbide of tungsten, niobium, tantalum, rhenium, or molybdenum. Additional carbide materials include silicon, titanium, hafnium, zirconium, or combinations thereof.
- the barrier coating 40 is a partially or fully stabilized zirconia, titanium nitride, silicon nitride, a silicon-aluminum-oxy-nitride (SiAlON), boron nitride, aluminum nitride, alumina (e.g., alpha-alumina), or any combination thereof.
- the barrier coating 40 is gadolinia and zirconia and may include 5-50 mol % gadolinia. The gadolinia and zirconia may include fluorite and a pyrochlore structure.
- the barrier coating 40 may be or may include a metallic coating.
- the metallic coating may be a platinum group metal, such as ruthenium, rhodium, palladium, osmium, iridium, and platinum. In other embodiments, the metallic coating may be a nickel alloy.
- the nickel alloy may consist essentially of up to 15 wt % cobalt, 5-18 wt % chromium, 7.5-12 wt % aluminum, 0.1-1.0 wt % yttrium, up to 0.06 wt % hafnium, up to 0.3 wt % silicon, 3-10 wt % tantalum, up to 5 wt % tungsten, 1-6 wt % rhenium, up to 10 wt % molybdenum, and a balance of nickel and any impurities.
- FIG. 3 illustrates another example component that is similar to the example shown in FIG. 2 except that the component additionally includes a bond coat 44 that mitigates any thermal expansion mismatch between the material of the substrate 42 and the material of the barrier coating 40 .
- the material of the bond coat 44 may be MCrAlY, where the M comprises at least one of nickel, cobalt, iron, or a combination thereof, Cr is chromium, Al is aluminum, and Y is yttrium.
- the bond coat 44 may be gamma-gamma prime nickel alloy or a nickel-based superalloy.
- the gamma-gamma prime nickel alloy may generally have a microstructure comprising nickel metal with phases of Ni 3 (AlTi) dispersed throughout the nickel metal.
- One example nickel-based superalloy has a nominal composition of 22 wt. % cobalt, 17 wt. % chromium, 12.5 wt. % aluminum, 0.6 wt. % yttrium, 0.4 wt. % silicon, 0.25 wt. % hafnium, and a balance of nickel and any impurities.
Abstract
A high temperature die casting system includes a die casting tool that has dies that are adapted for forming a component. The die casting tool is operable to heat and maintain a temperature of the dies above 500° F./260° C. At least a portion of the die casting tool that is exposed for contact with molten die casting material has a substrate and barrier coating on the substrate to protect from the molten die casting material.
Description
- This disclosure relates to die casting and, more specifically, a die casting system that has the ability to operate at high temperatures.
- In general, die casting is a process that includes moving molten metal into a die cavity to form a desired shape. The process typically includes transporting the molten metal into the die cavity, holding the metal in the cavity for a period of time until the casting solidifies, removing the casting from the die cavity, and trimming the casting to remove any scrap.
- A disclosed high temperature die casting system includes a die casting tool that has dies that are adapted for forming a component. Due to the nature of the process, the die casting tool is operable to heat and maintain a temperature of the dies above 500° F./260° C. At least a portion of the die casting tool that is exposed for contact with molten die casting material has a substrate and barrier coating on the substrate to protect from the molten die casting material.
- In another aspect, a high temperature die casting system includes a die casting tool having a substrate and a barrier coating on the substrate. The barrier coating is a material selected from partially or fully stabilized zirconia, titanium nitride, tungsten carbide, silicon carbide, silicon nitride, titanium carbide, silicon-oxygen-aluminum-nitrogen, hafnium carbide, zirconium carbide, and combinations thereof.
- An exemplary method for a high temperature die casting system includes maintaining a die casting tool having dies that are adapted for forming a component at a temperature above 500° F./260° C., and using a barrier coating on at least a portion of the die casting tool that is exposed for contact with molten die casting material to protect the underlying substrate of the die casting tool from contact with the molten die casting material.
- The various features and advantages of the disclosed examples will become apparent to those skilled in the art from the following detailed description. The drawings that accompany the detailed description can be briefly described as follows.
-
FIG. 1 illustrates an example die casting system. -
FIG. 2 illustrates an example die casting tool having a barrier coating. -
FIG. 3 illustrates another example die casting tool having a barrier coating and a bond coat. -
FIG. 1 illustrates adie casting system 10 including areusable die 12 having a plurality of dieelements 14, 16 that function to cast a component 15. The component 15 could include aeronautical components, such as a gas turbine engine blade or vane, or non-aeronautical components. Although twodie elements 14, 16 are depicted byFIG. 1 , it should be understood that the die 12 could include more or fewer die elements, as well as other parts and other configurations. - The die 12 is assembled by positioning the die
elements 14, 16 together and holding the dieelements 14, 16 at a desired position via amechanism 18. Themechanism 18 could include a clamping mechanism of appropriate hydraulic, pneumatic, electromechanical, and/or other configurations. Themechanism 18 also separates the dieelements 14, 16 subsequent to casting. - The die
elements 14, 16 include internal surfaces that cooperate to define a diecavity 20. The dieelements 14, 16 may additionally include one or more heating elements 17 for heating and maintaining thedie cavity 20 at a desired temperature above 500° F./260° C. For instance, the heating elements may heat the dieelements 14, 16 up to 500° F./260° C. during initial start-up of the dieelements 14, 16, maintain the desired temperature during operation of thedie elements 14, 16, and maintain the desired temperature during thermal cycling as components are produced in thedie casting system 10. The heating elements 17 may be resistance heaters, induction heaters, a recirculating thermal medium, such as, but not limited to hot oil, or combinations of different kinds of heaters that are operable to heat thedie cavity 20 to the desired temperature and then maintain that temperature (e.g., via non-application of heat or in combination with a cooling element). Traditional casting dies are not commonly equipped to specifically heat the cavity and may be present in the system for the purpose of removing excess heat from the die. The elevated temperature of dieelements 14, 16 serves to reduce the temperature differential between the die elements and the molten die casting material to reduce heat checking. - A
shot tube 24 is in fluid communication with thedie cavity 20 via one ormore ports 26 that extend into thedie element 14, the die element 16 or both. Ashot tube plunger 28 is received within theshot tube 24 and is moveable between a retracted and injected position (in the direction of arrow A) within theshot tube 24 by amechanism 30. Ashaft 31 extends between themechanism 30 and theshot tube plunger 28. Themechanism 30 could include a hydraulic assembly or other suitable system, including, but not limited to, pneumatic, electromechanical, hydraulic or any combination of systems. - The
shot tube 24 is positioned to receive a charge of material from amelting unit 32, such as a crucible, for example. Themelting unit 32 may utilize any known technique for melting an ingot of metallic material to prepare molten metal for delivery to theshot tube 24, such as will be further discussed below. In this example, the charge of material is melted into molten metal by themelting unit 32 at a location that is separate from theshot tube 24 and thedie 12. However, other melting configurations are contemplated as within the scope of this disclosure. Theexample melting unit 32 is positioned in relative close proximity to thedie casting system 10 to reduce the transfer distance of the charge of material between themelting unit 32 and thedie casting system 10. - Materials used to die cast a component 15 with the
die casting system 10 include, but are not limited to, nickel-based super alloys, cobalt-based super alloys, titanium alloys, high temperature aluminum alloys, copper-based alloys, iron alloys, molybdenum, tungsten, niobium or other refractory metals. This disclosure is not limited to the disclosed alloys, and other high melting temperature materials may be utilized to die cast a component 15. As used in this disclosure, the term “high melting temperature material” is intended to include materials having a melting temperature of approximately 1500° F./815° C. and higher. - The charge of material is transferred from the
melting unit 32 to thedie casting system 10. For example, the charge of material may be poured into apour hole 33 of theshot tube 24. A sufficient amount of molten metal is poured into the shot tube to fill thedie cavity 20. Theshot tube plunger 28 is actuated to inject the charge of material under pressure from theshot tube 24 into thedie cavity 20 to cast the component 15. Although the casting of a single component is depicted, thedie casting system 10 could be configured to cast multiple components in a single shot. - Although not necessary for all materials, at least a part of the
die casting system 10 can be positioned within avacuum chamber 34 that includes avacuum source 35. A vacuum is applied in thevacuum chamber 34 via thevacuum source 35 to render a vacuum die casting process. Thevacuum chamber 34 provides a non-reactive environment for thedie casting system 10 that reduces reaction, contamination or other conditions that could detrimentally affect the quality of the die cast component, such as gas entrapment or the formation of oxides or nitrides within the die cast component that can occur from exposure to atmospheric gasses. In one example, thevacuum chamber 34 is maintained at a pressure between 1×10−3 Torr and 1×10−4 Torr, although other pressures are contemplated. The actual pressure of thevacuum chamber 34 will vary based upon the type of component 15 or alloy being cast, among other conditions and factors. In the illustrated example, each of themelting unit 32, theshot tube 24 and thedie 12 are positioned within thevacuum chamber 34 during the die casting process such that the melting, injecting and solidifying of the high melting temperature material are all performed under vacuum. In another example, thechamber 34 is backfilled with an inert gas, such as Argon, for example. - The example
die casting system 10 ofFIG. 1 is illustrative only and could include more or fewer sections, parts and/or components. This disclosure extends to all forms of die casting, including but not limited to, horizontal, inclined, or vertical die casting systems and other die casting configurations. - At casting temperatures that exceed 1500° F./815° C., traditional die casting tools rapidly wear out from heat checking and thermal fatigue. The wear is even more evident at higher casting temperatures of metals or metal alloys that have melting points above 2500° F./1371° C. The rapid wear renders traditional tooling unsuitable for high temperature die casting. In this regard, as will be explained in more detail below, the
die casting system 10 utilizes abarrier coating 40 that protects thedie casting system 10 from the effects of the high temperature molten die casting material. - High temperature differentials between a molten die casting material and walls of the die casting tooling can cause heat checking and reduce tool life. In the example, the
die casting system 10 includes the barrier coating 40 on at least a portion of the tool surfaces that are exposed for contact with the molten die casting material, to alleviate heat checking or other influences of the high temperature die casting material. In general, any of the components of thedie casting system 10 that has a surface that contacts the molten metal is considered to be a die casting tool or component. As an example, the surfaces of thedie cavity 20,shot tube 24,shot tube plunger 28,melting unit 32,pour hole 33, and any runners or gates may include thebarrier coating 40. -
FIG. 2 illustrates a selected portion of one such area that includes thebarrier coating 40 on asubstrate 42 of a given die casting tool. In this example, thebarrier coating 40 is deposited directly onto the surface of thesubstrate 42. Thesubstrate 42 may be any suitable material for the given component. As an example, thesubstrate 42 may be a superalloy, such as a nickel and/or cobalt alloy. It is to be understood, however, that the material of thesubstrate 42 is not limited to any particular composition and one of ordinary skill in the art would be able to recognize suitable materials to meet their particular needs. - The
barrier coating 40 forms a thermal barrier between the molten die casting material and theunderlying substrate 42. In that regard, the material of thebarrier coating 40 has a relatively high thermal resistance. For instance, thebarrier coating 40 may be a ceramic material, such as an oxide, a nitride, a carbide, a zirconia material, a gadolinia material or combinations thereof. - The oxide may be a combination of several different oxides, including at least one oxide and the balance comprising a first oxide. The first oxide may be selected from the group consisting of zirconia, ceria, and hafnia. The at least one oxide may have a formula A2O3, where A is selected from the group consisting of La, Pr, Nd, Sm, Eu, Th, In, Sc, Y, Dy, Ho, Er, Tm, Yb, Lu, and mixtures thereof.
- The carbide may be a refractory metal carbide, such as a carbide of tungsten, niobium, tantalum, rhenium, or molybdenum. Additional carbide materials include silicon, titanium, hafnium, zirconium, or combinations thereof. In some examples, the
barrier coating 40 is a partially or fully stabilized zirconia, titanium nitride, silicon nitride, a silicon-aluminum-oxy-nitride (SiAlON), boron nitride, aluminum nitride, alumina (e.g., alpha-alumina), or any combination thereof. In embodiments, thebarrier coating 40 is gadolinia and zirconia and may include 5-50 mol % gadolinia. The gadolinia and zirconia may include fluorite and a pyrochlore structure. - Alternatively, or in addition to any other materials for the
barrier coating 40, thebarrier coating 40 may be or may include a metallic coating. The metallic coating may be a platinum group metal, such as ruthenium, rhodium, palladium, osmium, iridium, and platinum. In other embodiments, the metallic coating may be a nickel alloy. For instance, the nickel alloy may consist essentially of up to 15 wt % cobalt, 5-18 wt % chromium, 7.5-12 wt % aluminum, 0.1-1.0 wt % yttrium, up to 0.06 wt % hafnium, up to 0.3 wt % silicon, 3-10 wt % tantalum, up to 5 wt % tungsten, 1-6 wt % rhenium, up to 10 wt % molybdenum, and a balance of nickel and any impurities. -
FIG. 3 illustrates another example component that is similar to the example shown inFIG. 2 except that the component additionally includes abond coat 44 that mitigates any thermal expansion mismatch between the material of thesubstrate 42 and the material of thebarrier coating 40. For instance, the material of thebond coat 44 may be MCrAlY, where the M comprises at least one of nickel, cobalt, iron, or a combination thereof, Cr is chromium, Al is aluminum, and Y is yttrium. Alternatively, thebond coat 44 may be gamma-gamma prime nickel alloy or a nickel-based superalloy. The gamma-gamma prime nickel alloy may generally have a microstructure comprising nickel metal with phases of Ni3(AlTi) dispersed throughout the nickel metal. One example nickel-based superalloy has a nominal composition of 22 wt. % cobalt, 17 wt. % chromium, 12.5 wt. % aluminum, 0.6 wt. % yttrium, 0.4 wt. % silicon, 0.25 wt. % hafnium, and a balance of nickel and any impurities. - Although a combination of features is shown in the illustrated examples, not all of them need to be combined to realize the benefits of various embodiments of this disclosure. In other words, a system designed according to an embodiment of this disclosure will not necessarily include all of the features shown in any one of the Figures or all of the portions schematically shown in the Figures. Moreover, selected features of one example embodiment may be combined with selected features of other example embodiments.
- The preceding description is exemplary rather than limiting in nature. Variations and modifications to the disclosed examples may become apparent to those skilled in the art that do not necessarily depart from the essence of this disclosure. The scope of legal protection given to this disclosure can only be determined by studying the following claims.
Claims (21)
1. A high temperature die casting system comprising:
a die casting tool having dies adapted for forming a component and being operable to heat and maintain a temperature of the dies above 500° F./260° C., wherein at least a portion of the die casting tool that is exposed for contact with molten die casting material comprises a substrate and barrier coating on the substrate.
2. The high temperature die casting system as recited in claim 1 , wherein the barrier coating is alumina.
3. The high temperature die casting system as recited in claim 1 , wherein the barrier coating is silicon nitride.
4. The high temperature die casting system as recited in claim 1 , wherein the barrier coating is a refractory metal carbide.
5. The high temperature die casting system as recited in claim 4 , wherein the refractory metal carbide is hafnium carbide.
6. The high temperature die casting system as recited in claim 4 , wherein the refractory metal carbide is zirconium carbide.
7. The high temperature die casting system as recited in claim 4 , wherein the refractory metal carbide is selected from a group consisting of titanium carbide, tungsten carbide, niobium carbide, tantalum carbide, rhenium carbide, molybdenum carbide, silicon carbide and combinations thereof.
8. The high temperature die casting system as recited in claim 1 , wherein the barrier coating is silicon-aluminum-oxy-nitride (SiAlON).
9. The high temperature die casting system as recited in claim 1 , wherein the barrier coating is selected from a group consisting of boron nitride and aluminum nitride.
10. The high temperature die casting system as recited in claim 1 , wherein the barrier coating is selected from a group consisting of gadolinia, zirconia, partially or fully stabilized zirconia material, and mixtures thereof.
11. The high temperature die casting system as recited in claim 1 , wherein the barrier coating comprises at least one oxide and the balance comprising a first oxide selected from the group consisting of zirconia, ceria, and hafnia, the at least one oxide having a formula A2O3 where A is selected from a group consisting of La, Pr, Nd, Sm, Eu, Th, In, Sc, Y, Dy, Ho, Er, Tm, Yb, Lu, and mixtures thereof.
12. The high temperature die casting system as recited in claim 1 , wherein the barrier coating includes a metallic coating selected from a group consisting of ruthenium, rhodium, palladium, osmium, iridium, platinum and combinations thereof.
13. The high temperature die casting system as recited in claim 1 , wherein the barrier coating is a nickel alloy consisting essentially of up to 15 wt % cobalt, 5-18 wt % chromium, 7.5-12 wt % aluminum, 0.1-1.0 wt % yttrium, up to 0.06 wt % hafnium, up to 0.3 wt % silicon, 3-10 wt % tantalum, up to 5 wt % tungsten, 1-6 wt % rhenium, up to 10 wt % molybdenum, and a balance of nickel and any impurities.
14. The high temperature die casting system as recited in claim 1 , further comprising a bond coat between the substrate and the barrier coating, and the bond coat is a material selected from a group consisting of MCrAlY, gamma-gamma prime nickel alloy, nickel-based superalloy, and combinations thereof.
15. The high temperature die casting system as recited in claim 1 , wherein the substrate is a superalloy material.
16. A high temperature die casting system comprising:
a die casting tool including a substrate and barrier coating on the substrate, wherein the barrier coating is a material selected from a group consisting of partially or fully stabilized zirconia, titanium nitride, tungsten carbide, silicon carbide, silicon nitride, titanium carbide, silicon-aluminum oxy nitride (SiAlON), hafnium carbide, zirconium carbide, and combinations thereof.
17. The high temperature die casting system as recited in claim 16 , wherein the barrier coating is a partially or fully stabilized zirconia.
18. The high temperature die casting system as recited in claim 16 , wherein the barrier coating is silicon-aluminum-oxy-nitride (SiAlON).
19. The high temperature die casting system as recited in claim 16 , wherein the barrier coating is hafnium carbide.
20. The high temperature die casting system as recited in claim 16 , wherein the barrier coating is zirconium carbide.
21. A method for a high temperature die casting system, the method comprising:
maintaining a die casting tool having dies adapted for forming a component at a temperature above 500° F./260° C.; and
using a barrier coating on at least a portion of the die casting tool that is exposed for contact with molten die casting material to protect an underlying substrate of the die casting tool from the molten die casting material.
Priority Applications (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US12/940,362 US20120111525A1 (en) | 2010-11-05 | 2010-11-05 | High temperature die casting apparatus and method therefor |
EP11187817.9A EP2450127B1 (en) | 2010-11-05 | 2011-11-04 | High temperature die casting apparatus and method therefor |
SG2011081510A SG180159A1 (en) | 2010-11-05 | 2011-11-04 | High temperature die casting apparatus and method therefor |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
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US12/940,362 US20120111525A1 (en) | 2010-11-05 | 2010-11-05 | High temperature die casting apparatus and method therefor |
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US20120111525A1 true US20120111525A1 (en) | 2012-05-10 |
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Family Applications (1)
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US12/940,362 Abandoned US20120111525A1 (en) | 2010-11-05 | 2010-11-05 | High temperature die casting apparatus and method therefor |
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US (1) | US20120111525A1 (en) |
EP (1) | EP2450127B1 (en) |
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US20140352907A1 (en) * | 2011-12-15 | 2014-12-04 | Shenzhen Byd Auto R&D Company Limited | Die casting device and method for amorphous alloy |
US20170356304A1 (en) * | 2016-06-13 | 2017-12-14 | General Electric Company | Systems and methods for reducing fluid viscosity in a gas turbine engine |
US20180345360A1 (en) * | 2017-05-30 | 2018-12-06 | United Technologies Corporation | Oxidation resistant shot sleeve for high temperature die casting and method of making |
CN110684979A (en) * | 2019-11-01 | 2020-01-14 | 江苏锋泰工具有限公司 | Method for preparing hard alloy coating by cold spraying |
US20220290289A1 (en) * | 2021-03-10 | 2022-09-15 | Vapor Technologies, Inc. | Pvd coatings for aluminum die casting molds |
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US20220290289A1 (en) * | 2021-03-10 | 2022-09-15 | Vapor Technologies, Inc. | Pvd coatings for aluminum die casting molds |
Also Published As
Publication number | Publication date |
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EP2450127A3 (en) | 2016-07-13 |
EP2450127A2 (en) | 2012-05-09 |
EP2450127B1 (en) | 2019-10-09 |
SG180159A1 (en) | 2012-05-30 |
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