US3321005A - Method of making shell molds for casting reactive metals - Google Patents
Method of making shell molds for casting reactive metals Download PDFInfo
- Publication number
- US3321005A US3321005A US449294A US44929465A US3321005A US 3321005 A US3321005 A US 3321005A US 449294 A US449294 A US 449294A US 44929465 A US44929465 A US 44929465A US 3321005 A US3321005 A US 3321005A
- Authority
- US
- United States
- Prior art keywords
- mold
- ceramic
- metals
- organic
- dip coat
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Lifetime
Links
- 229910052751 metal Inorganic materials 0.000 title claims description 54
- 239000002184 metal Substances 0.000 title claims description 54
- 150000002739 metals Chemical class 0.000 title claims description 32
- 238000005266 casting Methods 0.000 title claims description 17
- 238000004519 manufacturing process Methods 0.000 title description 7
- 239000000203 mixture Substances 0.000 claims description 68
- 239000000919 ceramic Substances 0.000 claims description 45
- 238000000034 method Methods 0.000 claims description 37
- 239000002131 composite material Substances 0.000 claims description 16
- 239000002245 particle Substances 0.000 claims description 13
- 229910045601 alloy Inorganic materials 0.000 claims description 11
- 239000000956 alloy Substances 0.000 claims description 11
- 239000003870 refractory metal Substances 0.000 claims description 11
- 239000011368 organic material Substances 0.000 claims description 10
- 239000007787 solid Substances 0.000 claims description 10
- 238000005979 thermal decomposition reaction Methods 0.000 claims description 10
- 238000000354 decomposition reaction Methods 0.000 claims description 9
- 239000012530 fluid Substances 0.000 claims description 8
- 230000000737 periodic effect Effects 0.000 claims description 8
- 150000002894 organic compounds Chemical class 0.000 claims description 3
- 239000000047 product Substances 0.000 description 39
- 239000012260 resinous material Substances 0.000 description 24
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 17
- RCHKEJKUUXXBSM-UHFFFAOYSA-N n-benzyl-2-(3-formylindol-1-yl)acetamide Chemical compound C12=CC=CC=C2C(C=O)=CN1CC(=O)NCC1=CC=CC=C1 RCHKEJKUUXXBSM-UHFFFAOYSA-N 0.000 description 17
- 239000011230 binding agent Substances 0.000 description 15
- 239000000463 material Substances 0.000 description 14
- 230000001590 oxidative effect Effects 0.000 description 14
- 238000005470 impregnation Methods 0.000 description 13
- 235000013312 flour Nutrition 0.000 description 12
- 229910010293 ceramic material Inorganic materials 0.000 description 11
- 238000001035 drying Methods 0.000 description 9
- 238000010438 heat treatment Methods 0.000 description 9
- 238000006243 chemical reaction Methods 0.000 description 8
- HYBBIBNJHNGZAN-UHFFFAOYSA-N furfural Chemical compound O=CC1=CC=CO1 HYBBIBNJHNGZAN-UHFFFAOYSA-N 0.000 description 8
- GHMLBKRAJCXXBS-UHFFFAOYSA-N resorcinol Chemical compound OC1=CC=CC(O)=C1 GHMLBKRAJCXXBS-UHFFFAOYSA-N 0.000 description 8
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 7
- ISWSIDIOOBJBQZ-UHFFFAOYSA-N Phenol Chemical compound OC1=CC=CC=C1 ISWSIDIOOBJBQZ-UHFFFAOYSA-N 0.000 description 7
- 239000011248 coating agent Substances 0.000 description 7
- 238000000576 coating method Methods 0.000 description 7
- 238000009472 formulation Methods 0.000 description 7
- 238000002844 melting Methods 0.000 description 7
- 230000008018 melting Effects 0.000 description 7
- 238000009736 wetting Methods 0.000 description 7
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 description 6
- 230000000694 effects Effects 0.000 description 6
- 238000011065 in-situ storage Methods 0.000 description 6
- 230000000717 retained effect Effects 0.000 description 6
- 239000010936 titanium Substances 0.000 description 6
- 229910052719 titanium Inorganic materials 0.000 description 6
- GFQYVLUOOAAOGM-UHFFFAOYSA-N zirconium(iv) silicate Chemical compound [Zr+4].[O-][Si]([O-])([O-])[O-] GFQYVLUOOAAOGM-UHFFFAOYSA-N 0.000 description 6
- 239000011347 resin Substances 0.000 description 5
- 229920005989 resin Polymers 0.000 description 5
- 229910052845 zircon Inorganic materials 0.000 description 5
- 229910052726 zirconium Inorganic materials 0.000 description 5
- QTWJRLJHJPIABL-UHFFFAOYSA-N 2-methylphenol;3-methylphenol;4-methylphenol Chemical compound CC1=CC=C(O)C=C1.CC1=CC=CC(O)=C1.CC1=CC=CC=C1O QTWJRLJHJPIABL-UHFFFAOYSA-N 0.000 description 4
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 description 4
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 4
- CURLTUGMZLYLDI-UHFFFAOYSA-N Carbon dioxide Chemical compound O=C=O CURLTUGMZLYLDI-UHFFFAOYSA-N 0.000 description 4
- 229910052770 Uranium Inorganic materials 0.000 description 4
- QCWXUUIWCKQGHC-UHFFFAOYSA-N Zirconium Chemical compound [Zr] QCWXUUIWCKQGHC-UHFFFAOYSA-N 0.000 description 4
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 4
- 239000012736 aqueous medium Substances 0.000 description 4
- 229910052790 beryllium Inorganic materials 0.000 description 4
- ATBAMAFKBVZNFJ-UHFFFAOYSA-N beryllium atom Chemical compound [Be] ATBAMAFKBVZNFJ-UHFFFAOYSA-N 0.000 description 4
- 229910052799 carbon Inorganic materials 0.000 description 4
- 239000003575 carbonaceous material Substances 0.000 description 4
- 229930003836 cresol Natural products 0.000 description 4
- 239000005350 fused silica glass Substances 0.000 description 4
- 229910052735 hafnium Inorganic materials 0.000 description 4
- VBJZVLUMGGDVMO-UHFFFAOYSA-N hafnium atom Chemical compound [Hf] VBJZVLUMGGDVMO-UHFFFAOYSA-N 0.000 description 4
- JFALSRSLKYAFGM-UHFFFAOYSA-N uranium(0) Chemical compound [U] JFALSRSLKYAFGM-UHFFFAOYSA-N 0.000 description 4
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 4
- KFZMGEQAYNKOFK-UHFFFAOYSA-N Isopropanol Chemical compound CC(C)O KFZMGEQAYNKOFK-UHFFFAOYSA-N 0.000 description 3
- 229910000831 Steel Inorganic materials 0.000 description 3
- 239000008119 colloidal silica Substances 0.000 description 3
- 239000006185 dispersion Substances 0.000 description 3
- 238000011049 filling Methods 0.000 description 3
- 239000010439 graphite Substances 0.000 description 3
- 229910002804 graphite Inorganic materials 0.000 description 3
- 229910001385 heavy metal Inorganic materials 0.000 description 3
- 238000005058 metal casting Methods 0.000 description 3
- 229920000642 polymer Polymers 0.000 description 3
- 238000002360 preparation method Methods 0.000 description 3
- 230000001681 protective effect Effects 0.000 description 3
- 239000004576 sand Substances 0.000 description 3
- 239000000377 silicon dioxide Substances 0.000 description 3
- 239000002002 slurry Substances 0.000 description 3
- 239000010959 steel Substances 0.000 description 3
- ZOKXTWBITQBERF-UHFFFAOYSA-N Molybdenum Chemical compound [Mo] ZOKXTWBITQBERF-UHFFFAOYSA-N 0.000 description 2
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 2
- 229920002472 Starch Polymers 0.000 description 2
- 229910052786 argon Inorganic materials 0.000 description 2
- 235000014633 carbohydrates Nutrition 0.000 description 2
- 150000001720 carbohydrates Chemical class 0.000 description 2
- 229910002092 carbon dioxide Inorganic materials 0.000 description 2
- 239000001569 carbon dioxide Substances 0.000 description 2
- -1 casein Chemical class 0.000 description 2
- 229910052750 molybdenum Inorganic materials 0.000 description 2
- 239000011733 molybdenum Substances 0.000 description 2
- 239000000025 natural resin Substances 0.000 description 2
- 239000003960 organic solvent Substances 0.000 description 2
- 230000035515 penetration Effects 0.000 description 2
- 239000011253 protective coating Substances 0.000 description 2
- PUZPDOWCWNUUKD-UHFFFAOYSA-M sodium fluoride Chemical compound [F-].[Na+] PUZPDOWCWNUUKD-UHFFFAOYSA-M 0.000 description 2
- 235000019698 starch Nutrition 0.000 description 2
- WFKWXMTUELFFGS-UHFFFAOYSA-N tungsten Chemical compound [W] WFKWXMTUELFFGS-UHFFFAOYSA-N 0.000 description 2
- 229910052721 tungsten Inorganic materials 0.000 description 2
- 239000010937 tungsten Substances 0.000 description 2
- KPAPHODVWOVUJL-UHFFFAOYSA-N 1-benzofuran;1h-indene Chemical compound C1=CC=C2CC=CC2=C1.C1=CC=C2OC=CC2=C1 KPAPHODVWOVUJL-UHFFFAOYSA-N 0.000 description 1
- 244000215068 Acacia senegal Species 0.000 description 1
- 241000416162 Astragalus gummifer Species 0.000 description 1
- UGFAIRIUMAVXCW-UHFFFAOYSA-N Carbon monoxide Chemical compound [O+]#[C-] UGFAIRIUMAVXCW-UHFFFAOYSA-N 0.000 description 1
- 229920000818 Catalin Polymers 0.000 description 1
- 239000004859 Copal Substances 0.000 description 1
- 241000782205 Guibourtia conjugata Species 0.000 description 1
- 229920000084 Gum arabic Polymers 0.000 description 1
- BPQQTUXANYXVAA-UHFFFAOYSA-N Orthosilicate Chemical compound [O-][Si]([O-])([O-])[O-] BPQQTUXANYXVAA-UHFFFAOYSA-N 0.000 description 1
- 244000046052 Phaseolus vulgaris Species 0.000 description 1
- 235000010627 Phaseolus vulgaris Nutrition 0.000 description 1
- OKPNYGAWTYOBFZ-UHFFFAOYSA-N Pirenoxine Chemical compound C12=NC3=CC=CC=C3OC2=CC(=O)C2=C1C(=O)C=C(C(=O)O)N2 OKPNYGAWTYOBFZ-UHFFFAOYSA-N 0.000 description 1
- 229920001615 Tragacanth Polymers 0.000 description 1
- 235000010489 acacia gum Nutrition 0.000 description 1
- 239000000205 acacia gum Substances 0.000 description 1
- 125000005396 acrylic acid ester group Chemical group 0.000 description 1
- 235000010443 alginic acid Nutrition 0.000 description 1
- 229920000615 alginic acid Polymers 0.000 description 1
- INJRKJPEYSAMPD-UHFFFAOYSA-N aluminum;silicic acid;hydrate Chemical compound O.[Al].[Al].O[Si](O)(O)O INJRKJPEYSAMPD-UHFFFAOYSA-N 0.000 description 1
- 229910052614 beryl Inorganic materials 0.000 description 1
- 229910002091 carbon monoxide Inorganic materials 0.000 description 1
- 239000005018 casein Substances 0.000 description 1
- BECPQYXYKAMYBN-UHFFFAOYSA-N casein, tech. Chemical compound NCCCCC(C(O)=O)N=C(O)C(CC(O)=O)N=C(O)C(CCC(O)=N)N=C(O)C(CC(C)C)N=C(O)C(CCC(O)=O)N=C(O)C(CC(O)=O)N=C(O)C(CCC(O)=O)N=C(O)C(C(C)O)N=C(O)C(CCC(O)=N)N=C(O)C(CCC(O)=N)N=C(O)C(CCC(O)=N)N=C(O)C(CCC(O)=O)N=C(O)C(CCC(O)=O)N=C(O)C(COP(O)(O)=O)N=C(O)C(CCC(O)=N)N=C(O)C(N)CC1=CC=CC=C1 BECPQYXYKAMYBN-UHFFFAOYSA-N 0.000 description 1
- 235000021240 caseins Nutrition 0.000 description 1
- 230000015556 catabolic process Effects 0.000 description 1
- XFQYJNINHLZMIU-UHFFFAOYSA-N cataline Natural products CN1CC(O)C2=CC(OC)=C(OC)C3=C2C1CC1=C3C=C(OC)C(OC)=C1 XFQYJNINHLZMIU-UHFFFAOYSA-N 0.000 description 1
- 238000009750 centrifugal casting Methods 0.000 description 1
- 239000007795 chemical reaction product Substances 0.000 description 1
- 239000011280 coal tar Substances 0.000 description 1
- 229910017052 cobalt Inorganic materials 0.000 description 1
- 239000010941 cobalt Substances 0.000 description 1
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- 239000003085 diluting agent Substances 0.000 description 1
- KZHJGOXRZJKJNY-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Si]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O KZHJGOXRZJKJNY-UHFFFAOYSA-N 0.000 description 1
- 238000003618 dip coating Methods 0.000 description 1
- 238000007598 dipping method Methods 0.000 description 1
- 238000010304 firing Methods 0.000 description 1
- VOOLKNUJNPZAHE-UHFFFAOYSA-N formaldehyde;2-methylphenol Chemical compound O=C.CC1=CC=CC=C1O VOOLKNUJNPZAHE-UHFFFAOYSA-N 0.000 description 1
- GZGAFEPNUDSSJF-UHFFFAOYSA-N formaldehyde;furan-2-carbaldehyde Chemical compound O=C.O=CC1=CC=CO1 GZGAFEPNUDSSJF-UHFFFAOYSA-N 0.000 description 1
- 239000011521 glass Substances 0.000 description 1
- 235000010985 glycerol esters of wood rosin Nutrition 0.000 description 1
- 230000005484 gravity Effects 0.000 description 1
- 238000007654 immersion Methods 0.000 description 1
- 230000003116 impacting effect Effects 0.000 description 1
- 238000010348 incorporation Methods 0.000 description 1
- 239000011261 inert gas Substances 0.000 description 1
- 229910010272 inorganic material Inorganic materials 0.000 description 1
- 239000011147 inorganic material Substances 0.000 description 1
- 230000010354 integration Effects 0.000 description 1
- 238000005495 investment casting Methods 0.000 description 1
- 239000010443 kyanite Substances 0.000 description 1
- 229910052850 kyanite Inorganic materials 0.000 description 1
- QSHDDOUJBYECFT-UHFFFAOYSA-N mercury Chemical compound [Hg] QSHDDOUJBYECFT-UHFFFAOYSA-N 0.000 description 1
- 229910052753 mercury Inorganic materials 0.000 description 1
- 238000000465 moulding Methods 0.000 description 1
- 229910052863 mullite Inorganic materials 0.000 description 1
- 229910052759 nickel Inorganic materials 0.000 description 1
- 229910052757 nitrogen Inorganic materials 0.000 description 1
- MWUXSHHQAYIFBG-UHFFFAOYSA-N nitrogen oxide Inorganic materials O=[N] MWUXSHHQAYIFBG-UHFFFAOYSA-N 0.000 description 1
- 230000003647 oxidation Effects 0.000 description 1
- 238000007254 oxidation reaction Methods 0.000 description 1
- 239000003208 petroleum Substances 0.000 description 1
- 229920001568 phenolic resin Polymers 0.000 description 1
- 239000004033 plastic Substances 0.000 description 1
- BDERNNFJNOPAEC-UHFFFAOYSA-N propan-1-ol Chemical compound CCCO BDERNNFJNOPAEC-UHFFFAOYSA-N 0.000 description 1
- 235000018102 proteins Nutrition 0.000 description 1
- 102000004169 proteins and genes Human genes 0.000 description 1
- 108090000623 proteins and genes Proteins 0.000 description 1
- LIVNPJMFVYWSIS-UHFFFAOYSA-N silicon monoxide Chemical class [Si-]#[O+] LIVNPJMFVYWSIS-UHFFFAOYSA-N 0.000 description 1
- 229910052814 silicon oxide Inorganic materials 0.000 description 1
- 235000013024 sodium fluoride Nutrition 0.000 description 1
- 239000011775 sodium fluoride Substances 0.000 description 1
- 239000002904 solvent Substances 0.000 description 1
- 238000005507 spraying Methods 0.000 description 1
- 230000006641 stabilisation Effects 0.000 description 1
- 238000011105 stabilization Methods 0.000 description 1
- 239000008107 starch Substances 0.000 description 1
- 238000000859 sublimation Methods 0.000 description 1
- 230000008022 sublimation Effects 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 235000000346 sugar Nutrition 0.000 description 1
- 150000008163 sugars Chemical class 0.000 description 1
- 229920003002 synthetic resin Polymers 0.000 description 1
- 239000000057 synthetic resin Substances 0.000 description 1
- 235000007586 terpenes Nutrition 0.000 description 1
- 150000003505 terpenes Chemical class 0.000 description 1
- ZCUFMDLYAMJYST-UHFFFAOYSA-N thorium dioxide Chemical compound O=[Th]=O ZCUFMDLYAMJYST-UHFFFAOYSA-N 0.000 description 1
Classifications
-
- 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
-
- 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
- B22C1/165—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 in the manufacture of multilayered shell moulds
Definitions
- the invention will be described with reference to the preparation and use of a mold formed about a heat or otherwise disposable pattern by repeatedly wetting with a dip coat composition and stuccoing to build up a monolithic structure from which the pattern is removed to leave a corresponding mold cavity into which molten metal may be directly cast to produce a metal product having a shape corresponding to the cavity left by the removed pattern.
- the concepts of this invention Will have application also to the mold that is formed by investment of the monolithic structure in a ceramic body for support, in accordance with conventional investment casting procedures, but it is preferred to make use of the monolithic structure without investment when suflicient strength can be embodied in the walls of the monolithic structure to enable the molten metal to be poured directly therein without support.
- such monolithic mold structures are produced by immersion of a cluster of wax patterns into a dip coat composition formulated of an inorganic binder, such as colloidal silica, and a ceramic flour such as is formed of silica, zircon, alumina, fused quartz and the like.
- an inorganic binder such as colloidal silica
- a ceramic flour such as is formed of silica, zircon, alumina, fused quartz and the like.
- a stucco such as larger particles of silica, zircon, alundum, fused quartz and the like ceramic materials
- This procedure of wetting with the dip coat composition and stuccoing is repeated for a number of times with intermediate drying until a composite layer of the desired thickness and strength has been built up about the cluster formed of a number of the patterns of wax or other preferably heat disposable material.
- the assembly is heated to a temperature above the melting point temperature of the wax to remove the pattern and the remaining mold, having a mold cavity corresponding in shape to the displaced pattern, is fired at an elevated temperature in the range of l5002300' F. to cure the mold.
- molds of the type described are suitable for use in casting shaped products of steels and alloys of steels including steels alloyed with nickel, cobalt and the like, they have been found to be unsuitable for use in the casting of shaped products from such high melting point metals as the refractory metals or reactive heavy metals such as titanium, zirconium, uranium, hafnium, beryllium, or other metals of the group IV-b series.
- One of the major difficulties stems from the reactions that take place at the elevated temperature of the molten metal between the molten metals and the silicon oxides or ceramic components making up the mold. This results not only in an imperfect casting or a casting in which the reaction which takes place at the surface produces an imperfect casting but the reactions taking place operate also to ice modify the chemistry of the cast product and to produce an unsound casting.
- colloidal graphite is incorporated as a component in the dip coat composition to coat the individual ceramic particles with the non-reactive colloidal graphite. While some improvement is derived from the described combination of colloidal graphite with the ceramic particles of the dip coat composition, a continuous protective surface is not made available whereby undesirable reactions are still capable of taking place.
- a mold formed of ceramic material of the types described can be used in the production of shaped products of metals of the types described and alloys thereof when the individual particles of the ceramic materials making up the mold portion immediately surrounding the mold cavity, and preferably the entire crosssection of the mold walls, are provided with a substantially continuous coating of an inert carbonaceous material formed in situ in the mold by thermal decomposition of an organic material and preferably by thermal decomposition of an organic resinous material such as a phenol aldehyde resin, cresol aldehyde resin, furfural aldehyde resin, resorcinol aldehyde resin, acrylic acid ester polymer, and the like.
- the thermally reducible organic resinous material can be incorporated into the mold by formulation of the resinous material as a part of the dip coat composition whereby such organic resinous component will become uniformly distributed substantially throughout the cross-section of the mold wall that is formed about the disposable pattern.
- the organic resinous component can be introduced into the mold Walls after removal of the disposable pattern by impregnation of the resulting mold with a dilute solution or dispersion of the organic resinous component in a suitable solvent or aqueous medium.
- the resinous component will thermally break down to a tenacious carbonaceous residue of an inert form of carbon or carbonaceous material which will effectively coat the inorganic or ceramic particles in at least the portions of the mold adjacent the mold cavity. This will result in a substantially continuous covering which will protect the ceramic or inorganic materials to enable the described molten metals or alloys to be poured directly into the mold cavity without reaction with components making up the mold.
- the organic resinous component when the organic resinous component is incorporated to form a part of the dip coat composition, the organic resinous component can be embodied in the dip coat composition in addition to the conventional ceramic binder, such as colloidal silica. Instead, the inorganic binder component can be eliminated whereby the organic resinous material will function in the dip coat composition as an interim binder for the buildup of the layers of ceramic flour and stucco.
- the dip coat composition can be formulated to contain the organic resinous component in an amount within the range of 40% by weight and preferably in an amount within the range of 25% by weight.
- the amount of organic resinous component is preferably increased to within the range of 10-40% by weight and preferably an amount within the range of -30% by weight of the dip coat composition.
- the organic resinous component in a dissolved state so as to form a coating about the ceramic particles upon drying.
- a diluent in the form of a conventional aqueous medium when the resinous component is in a water soluble or A stage.
- the dip coat composition can be formulated with an organic solvent in which the resinous material is soluble or the organic resinous component can be incorporated as a dispersed phase in the aqueous medium to enable formulation of the dip coat composition as an aqueous system.
- the organic resinous material When the organic resinous material is incorporated by way of impregnation of an already formed mold, it is desirable to make use of the organic resinous material in a dilute solution in an organic solvent or a dilute dispersion in an aqueous medium.
- the amount of the organic resinous component formulated into the impregnating composition will depend somewhat on the character and the molecular weight of the resinous system. As a general rule, a satisfactory impregnating composition can be formulated with the organic resinous component present in an amount within the range of 1-80% by weight and preferably 2-10% by weight. It will be understood that when a larger amount of resinous material is required in the formed mold, the impregnation process can be repeated one or more times.
- a cluster of wax patterns is formed in the conventional manner by attachment of the patterns to runners, also formed of wax or other heat disposable materials, and to a funnel or cup which communicates with the runners to define the opening in the mold through which the molten metal is poured for filling the mold cavity.
- the patterns, runners and/or funnel can be formed or plastic or other heat disposable materials, or of materials which can be disposed of by chemical solution, sublimation or by mere increase to room temperature, as in the frozen mercury process.
- the cluster should be inspected for the removal of dirt, flakes or other materials which might have adhered to the surfaces of the patterns and which, if allowed to remain, would reproduce and provide imperfections in the surfaces of the metal casting.
- Example 1 Dip coat composition (with ceramic binder): Colloidal silica (30% grade, 1.198 specific gravity) cc 8000 Zircon (99% through 325 mesh) pounds 165 Water cc 6150 Water soluble A-stage phenol aldehyde resin pounds 30 Sodium fluoride grams 110
- Example 2 Dip coat composition (without ceramic binder):
- Liquid phenol formaldehyde resin (Catalin 136) 27 Isopropyl alcohol 35 Silica flour (-325 mesh) 38
- the cleaned cluster is immersed in the slurry c0mpris ing the dip coat composition to wet all of the surfaces with the exception of the lip of the pouring spout. Instead of dipping, the surfaces can be wet with the slurry of the dip coat composition by other coating techniques, such as by flow coating, spray coating and the like.
- a finely divided, dry stucco is sprinkled over the surfaces whereby some of the stucco will adhere to the wet coating of the dip coat composition and be retained on the surfaces of the pattern for integration with the slurry of the dip coat composition to form a composite layer therewith about the cluster.
- the stucco can also be applied onto the wet surfaces of the cluster by means of a moving bed into which the cluster is immersed substantially completely to coat the wet surfaces of the cluster with the stucco material.
- the stucco use can be made of alumina, zircon, silicate, fused silica, with or without resinous pretreatment, and in which the stucco is dimensioned, at least in the first few coats, to be less than 50 mesh but more than mesh.
- the cycle of wetting with the dip coat composition and stuccoing is repeated a number of times, with intermediate drying between each cycle, until -a composite layer of the desired thickness has been built up about the walls of the cluster including the patterns and parts.
- a mold having a wall thickness built up to about A to /2 inch usually provides strength suflicient for investment or to enable the molten metal to be poured directly into the mold for the production of shaped metal products of normal weight.
- the buildup of walls of greater thickness can be produced for use in the molding of larger and heavy castings.
- a wall thickness of A to /2 inch can be achieved with from five to ten cycles of dip coating, stuccoing, and intermediate drying.
- dip coat compositions of the same formulation for all cycles thereby uniformly to distribute the organic resinous material throughout the cross-section of the mold wall, it will be sufficient if only the inner one-half of the wall cross section is formed of the dip coat composition containing the organic resinous component while the remainder of the built-up wall is formed of a conventional dip coat composition formulated with ceramic materials.
- the composite structure is dewaxed by inverting the mold and by heating to a temperature above the melting point temperature for the wax and preferably to a temperature above 400 F. but below the temperature at which the organic resinous material will be burned out of the mold.
- Dewaxing can be carried out by other processes such as hot sand dewaxing wherein the mold is surrounded with sand preheated to a temperature within the range of 400-800 F. or in which the hot sand is poured over the mold; steam dewaxing wherein the composite structure is housed in an autoclave or else steam at high pressure is introduced onto the mold.
- the dewaxing step can be carried out as a separate operation in the manner described but it is preferred to combine the dewaxing step with the subsequent step of curing the mold wherein the mold, with the wax pattern or after the wax pattern has been removed by one or the other of the dewaxing processes, is introduced into a zone heated to a temperature above 800 F. and preferably to a temperature within the range of 1000- 2300 F. while the atmosphere in the zone is maintained as an inert or non-oxidizing or reducing atmosphere, as by the use of an inert gas such as argon, nitrogen, carbon dioxide and the like.
- an inert gas such as argon, nitrogen, carbon dioxide and the like.
- the mold is cured and the organic resinous component is thermally decomposed to a stable form of carbon or carbonaceous decomposition product which effectively coats the adjacent ceramic materials with a protective coating that blocks reaction between the ceramic and hot molten metals poured into the cavity of the mold.
- the desired cure and thermal breakdown of the organic resinous material can usually be achieved at the there is no harm in heating for a longer period of time to insure complete stabilization of the materials making up the mold.
- the carbonaceous decomposition product that is formed is of the type which either swells or otherwise operates to fill up interstices of the mold since the formed mold is less pervious to the penetration of the molten metal poured into the mold cavity while still providing microporous openings through which the mold can breathe thereby to block reaction between .the metal and the materials of the mold while at the same time providing a more uniform smooth surface at the interface for the production of a molded product which conforms more exactly with the original shape of the mold cavity and with less surface imperfection.
- an acceptable product of such metals which have heretofore been incapable of being processed in ceramic molds.
- a solution of .5% to 25% by weight furfural formaldehyde resin or a solution of .5% to 80% by Weight of a phenol or cresol formaldehyde resin in propanol is poured into the mold cavity for flow as by impregnation into the interstices of the porous mold.
- the step of impregnation can be repeated one or more times if a higher concentration of the organic resinous component is desired in the mold walls.
- the step of pour ing the impregnating composition into the mold is followed by removal of the material that remains and by drying before subsequent re-introduction of impregnating composition for increasing the amount of material introduced into the mold walls.
- the dried resinous material coats the ceramic flour and stucco making up the ad jacent portions of the mold walls.
- the mold is fired in the manner previously described for curing in an inert or non-oxidizing atmosphere to effect the thermal decomposition of the impregnating organic resinous material for reduction thereof to temperature described in from 15 to minutes but the inert carbonaceous decomposition product coating the ceramic particles of the mold and filling the interstices of the mold to block penetration of molten metal poured into the mold cavity during the subsequent. steps of metal casting.
- both of the prevously de scribed systems may be combined to produce a mold having the organic resinous component incorporated into the walls of the mold by way of a dip coat composition and in which additional organic resinous material is incorporated, at least in the inner portions of the mold about the mold cavity, by the subsequent process of impregnation.
- the stabilized thermal decomposition product formed of the organic resinous component is capable also of the characteristics of a binder in the cured product since a mold of the desired strength results even though no ceramic binder is present in the dip coat composition.
- organic materials which are easily thermally decomposable to a stabilized carbon or carbonaceous reaction product can be employed as the organic component in the amounts described for the organic resinous material in the preceding examples.
- Such other materials which can be substituted for the organic resinous materials in equivalent amounts in the foregoing examples include natural resins and gums, such as copal resin, ester gum, gum tragacanth, gum arabic, terpene resins, coumarone indene resins and the like; sugars, carbohydrates and starches such as casein, albumen, algins and the like; coal tar and petroleum resins and the like.
- Molten metal can be poured directly :into the mold cavity for the fabrication of molded products since the mold possesses sufiicient strength and has sufficient mass integrity to enable the motlen metal to be poured directly into the mold.
- preheating is not essential, it is desirable to preheat the mold prior to metal pouring. If the graphitized mold is to be preheated to a temperature above 800 F, it is desirable either to effect such preheat under vacuum conditions or in an inert or non-oxidizing atmosphere, as in an atmosphere of argon, nitrogen or carbon monoxide or carbon dioxide, otherwise the carbonaceous product will burn from the mold.
- the described refractory metals, reactive heavy metals or metals of the group IV-b have a melting point far in excess of 800 B, it is desirable to achieve metal pouring by vacuum casting techniques wherein the mold is enclosed within a vacuum chamber which communicates with a melting furnace whereby a vacuum can be drawn to evacuate the chamber and the mold prior to metal poun'ng.
- the mold and metal cast therein are preferably maintained under vacuum conditions until the poured metal has solidified or cooled to a temperature below 800 F. Thereafter, the assembly can be removed from the vacuum chamber for further processing.
- centrifugal casting techniques can be employed in combination with metal pouring.
- description will be made of the use of a mold embodying the features of this invention in the preparation of a cast metal product of titanium, it being understood that others of the heretofore described refractory metals, heavy reactive metals or metals of group lV-b and alloys thereof may be similarly processed.
- the mold is housed in a vacuum chamber on the underside of a melting furnace and the molten titanium is poured under vacuum into the mold, with or without preheating the mold.
- preheating it is desirable to preheat the mold while under vacuum conditions in which the preheat may be to a temperature up to 800 F. although preheating to higher temperatures is preferred.
- the poured metal is allowed to cool in the vacuum chamber or under a protective inert or non-oxidizing atmosphere to a temperature below that at which oxidation of the carbonaceous material can take place before removal :of the cast metal product from the protective atmosphere of the mold.
- the cast metal product can be removed by conventional techniques such as by impacting and shaking to disintegrate the mold and free the casting.
- ceramic flour and ceramic stucco are intended to include flour and stucco formed of ceramic materials such as silica, fused glass, fused quartz, Zirconium silicates, ores such as beryl ores, thoria, zirconite, kyanite, mullite and sillamanite, and oxides of the types previously described including zircon and alumina.
- organic resinous binder is selected from the group consisting of phenol aldehyde resin, cresol aldehyde resin, resorcinol aldehyde resin, and furfural aldehyde resin.
- the organic component of the dip coat composition is selected from the group consisting of a synthetic resin, a natural resin, a gum, starch, a protein, and a carbohydrate.
- the organic resinous component is selected from the group consisting of a phenol aldehyde resin, a cresol aldehyde resin, a resorcinol aldehyde resin, and a furfural aldehyde resin.
- the mold is formed of a composite of a dip coat composition the solids of which consist essentially of a ceramic flour and a ceramic binder and a stucco of ceramic particles, the steps of impregnating the mold with a dilute fluid composition containing an organic compound which is easily thermally decomposable to a stable carbonaceous decomposition product, firing the impregnated mold in a non-oxidizing atmosphere to a temperature above the thermal decomposition temperature for the organic material thermally to decompose the organic material in situ in the impregnated mold.
- the organic resinous polymer is selected from the group consisting of a phenol aldehyde resin, a cresol aldehyde resin,
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Materials Engineering (AREA)
- Mold Materials And Core Materials (AREA)
Priority Applications (5)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US449294A US3321005A (en) | 1965-04-19 | 1965-04-19 | Method of making shell molds for casting reactive metals |
BE679564D BE679564A (enrdf_load_stackoverflow) | 1965-04-19 | 1966-04-15 | |
NL6605151A NL6605151A (enrdf_load_stackoverflow) | 1965-04-19 | 1966-04-18 | |
SE05238/66A SE346711B (enrdf_load_stackoverflow) | 1965-04-19 | 1966-04-18 | |
FR1476352D FR1476352A (fr) | 1965-03-22 | 1966-04-19 | Procédé pour le moulage des métaux et alliages et moule obtenu selon ce procédé |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US449294A US3321005A (en) | 1965-04-19 | 1965-04-19 | Method of making shell molds for casting reactive metals |
US481728A US3296666A (en) | 1965-08-23 | 1965-08-23 | Method of preparing an investment mold for use in precision casting |
Publications (1)
Publication Number | Publication Date |
---|---|
US3321005A true US3321005A (en) | 1967-05-23 |
Family
ID=27035664
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US449294A Expired - Lifetime US3321005A (en) | 1965-03-22 | 1965-04-19 | Method of making shell molds for casting reactive metals |
Country Status (4)
Country | Link |
---|---|
US (1) | US3321005A (enrdf_load_stackoverflow) |
BE (1) | BE679564A (enrdf_load_stackoverflow) |
NL (1) | NL6605151A (enrdf_load_stackoverflow) |
SE (1) | SE346711B (enrdf_load_stackoverflow) |
Cited By (8)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3485288A (en) * | 1967-03-13 | 1969-12-23 | Precision Castparts Corp | Method of making a mold for casting of refractory and reactive metals |
US3498359A (en) * | 1966-03-09 | 1970-03-03 | Imp Metal Ind Kynoch Ltd | Moulds for use in metal casting |
US6634413B2 (en) | 2001-06-11 | 2003-10-21 | Santoku America, Inc. | Centrifugal casting of nickel base superalloys in isotropic graphite molds under vacuum |
US6705385B2 (en) | 2001-05-23 | 2004-03-16 | Santoku America, Inc. | Castings of metallic alloys with improved surface quality, structural integrity and mechanical properties fabricated in anisotropic pyrolytic graphite molds under vacuum |
US20040060685A1 (en) * | 2001-06-11 | 2004-04-01 | Ranjan Ray | Centrifugal casting of titanium alloys with improved surface quality, structural integrity and mechanical properties in isotropic graphite molds under vacuum |
US6799626B2 (en) | 2001-05-15 | 2004-10-05 | Santoku America, Inc. | Castings of metallic alloys with improved surface quality, structural integrity and mechanical properties fabricated in finegrained isotropic graphite molds under vacuum |
US6799627B2 (en) | 2002-06-10 | 2004-10-05 | Santoku America, Inc. | Castings of metallic alloys with improved surface quality, structural integrity and mechanical properties fabricated in titanium carbide coated graphite molds under vacuum |
US20050016706A1 (en) * | 2003-07-23 | 2005-01-27 | Ranjan Ray | Castings of metallic alloys with improved surface quality, structural integrity and mechanical properties fabricated in refractory metals and refractory metal carbides coated graphite molds under vacuum |
Citations (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US2683296A (en) * | 1951-11-17 | 1954-07-13 | Monsanto Chemicals | Method of preparing shell molds and composition therefor |
US2886869A (en) * | 1956-08-01 | 1959-05-19 | John M Webb | Graphite refractory molds and method of making same |
US2961751A (en) * | 1958-01-13 | 1960-11-29 | Misco P C Inc | Ceramic metal casting process |
US2991267A (en) * | 1957-04-10 | 1961-07-04 | Morris Bean & Company | Coated sand and method of making the same |
US3005244A (en) * | 1958-06-09 | 1961-10-24 | Howe Sound Co | Production of shell molds |
US3042541A (en) * | 1958-04-16 | 1962-07-03 | Albi Mfg Company Inc | Method of treating a casting mold and the treated mold |
-
1965
- 1965-04-19 US US449294A patent/US3321005A/en not_active Expired - Lifetime
-
1966
- 1966-04-15 BE BE679564D patent/BE679564A/xx unknown
- 1966-04-18 NL NL6605151A patent/NL6605151A/xx unknown
- 1966-04-18 SE SE05238/66A patent/SE346711B/xx unknown
Patent Citations (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US2683296A (en) * | 1951-11-17 | 1954-07-13 | Monsanto Chemicals | Method of preparing shell molds and composition therefor |
US2886869A (en) * | 1956-08-01 | 1959-05-19 | John M Webb | Graphite refractory molds and method of making same |
US2991267A (en) * | 1957-04-10 | 1961-07-04 | Morris Bean & Company | Coated sand and method of making the same |
US2961751A (en) * | 1958-01-13 | 1960-11-29 | Misco P C Inc | Ceramic metal casting process |
US3042541A (en) * | 1958-04-16 | 1962-07-03 | Albi Mfg Company Inc | Method of treating a casting mold and the treated mold |
US3005244A (en) * | 1958-06-09 | 1961-10-24 | Howe Sound Co | Production of shell molds |
Cited By (11)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3498359A (en) * | 1966-03-09 | 1970-03-03 | Imp Metal Ind Kynoch Ltd | Moulds for use in metal casting |
US3485288A (en) * | 1967-03-13 | 1969-12-23 | Precision Castparts Corp | Method of making a mold for casting of refractory and reactive metals |
US6799626B2 (en) | 2001-05-15 | 2004-10-05 | Santoku America, Inc. | Castings of metallic alloys with improved surface quality, structural integrity and mechanical properties fabricated in finegrained isotropic graphite molds under vacuum |
US6705385B2 (en) | 2001-05-23 | 2004-03-16 | Santoku America, Inc. | Castings of metallic alloys with improved surface quality, structural integrity and mechanical properties fabricated in anisotropic pyrolytic graphite molds under vacuum |
US6634413B2 (en) | 2001-06-11 | 2003-10-21 | Santoku America, Inc. | Centrifugal casting of nickel base superalloys in isotropic graphite molds under vacuum |
US20040060685A1 (en) * | 2001-06-11 | 2004-04-01 | Ranjan Ray | Centrifugal casting of titanium alloys with improved surface quality, structural integrity and mechanical properties in isotropic graphite molds under vacuum |
US6755239B2 (en) | 2001-06-11 | 2004-06-29 | Santoku America, Inc. | Centrifugal casting of titanium alloys with improved surface quality, structural integrity and mechanical properties in isotropic graphite molds under vacuum |
US6776214B2 (en) | 2001-06-11 | 2004-08-17 | Santoku America, Inc. | Centrifugal casting of titanium alloys with improved surface quality, structural integrity and mechanical properties in isotropic graphite molds under vacuum |
US6799627B2 (en) | 2002-06-10 | 2004-10-05 | Santoku America, Inc. | Castings of metallic alloys with improved surface quality, structural integrity and mechanical properties fabricated in titanium carbide coated graphite molds under vacuum |
US20050016706A1 (en) * | 2003-07-23 | 2005-01-27 | Ranjan Ray | Castings of metallic alloys with improved surface quality, structural integrity and mechanical properties fabricated in refractory metals and refractory metal carbides coated graphite molds under vacuum |
US6986381B2 (en) | 2003-07-23 | 2006-01-17 | Santoku America, Inc. | Castings of metallic alloys with improved surface quality, structural integrity and mechanical properties fabricated in refractory metals and refractory metal carbides coated graphite molds under vacuum |
Also Published As
Publication number | Publication date |
---|---|
NL6605151A (enrdf_load_stackoverflow) | 1966-10-20 |
SE346711B (enrdf_load_stackoverflow) | 1972-07-17 |
BE679564A (enrdf_load_stackoverflow) | 1966-10-17 |
Similar Documents
Publication | Publication Date | Title |
---|---|---|
US5027878A (en) | Method of impregnation of iron with a wear resistant material | |
US3422880A (en) | Method of making investment shell molds for the high integrity precision casting of reactive and refractory metals | |
US3204303A (en) | Precision investment casting | |
US3256574A (en) | Mold and method of fabrication | |
US3537949A (en) | Investment shell molds for the high integrity precision casting of reactive and refractory metals,and methods for their manufacture | |
US3266106A (en) | Graphite mold and fabrication method | |
US3835913A (en) | Investment casting | |
US2886869A (en) | Graphite refractory molds and method of making same | |
US3296666A (en) | Method of preparing an investment mold for use in precision casting | |
US3321005A (en) | Method of making shell molds for casting reactive metals | |
US2948935A (en) | Process of making refractory shell for casting metal | |
US3094751A (en) | Method of form removal from precision casting shells | |
US3241200A (en) | Precision mold and method of fabrication | |
EP0020373B1 (en) | Method of making and using a ceramic shell mold | |
US3019497A (en) | Making fine grained castings | |
US3211560A (en) | Mold wash composition and casting mold coated therewith | |
US3688832A (en) | Refractory cores | |
US3153826A (en) | Precision casting molds and techniques | |
US2749586A (en) | Process of forming shell mold | |
US3239897A (en) | Precision casting mold and methods and materials for production and use | |
US3349830A (en) | Method of making a casting mold | |
US2820268A (en) | Method of making shell molds with thin core | |
US6673141B2 (en) | Foundry sand with oxidation promoter | |
US3259948A (en) | Making fine grained castings | |
US4223716A (en) | Method of making and using a ceramic shell mold |
Legal Events
Date | Code | Title | Description |
---|---|---|---|
AS | Assignment |
Owner name: HOWMET TURBINE COMPONENTS CORPORATION 825 THIRD AV Free format text: ASSIGNMENT OF ASSIGNORS INTEREST. SUBJECT TO AGREEMENT DATED DECEMBER 31, 1975.;ASSIGNOR:HOWMET CORPORATON A CORP. OF DE;REEL/FRAME:004164/0321 Effective date: 19830705 |