US3598172A - Process of casting with downward-unidirectional solidification - Google Patents

Process of casting with downward-unidirectional solidification Download PDF

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US3598172A
US3598172A US872562A US3598172DA US3598172A US 3598172 A US3598172 A US 3598172A US 872562 A US872562 A US 872562A US 3598172D A US3598172D A US 3598172DA US 3598172 A US3598172 A US 3598172A
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alloy
mold
cavity
filling
article
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US872562A
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Stephen M Copley
Anthony F Giamei
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Raytheon Technologies Corp
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United Aircraft Corp
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22DCASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D27/00Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting
    • B22D27/04Influencing the temperature of the metal, e.g. by heating or cooling the mould
    • B22D27/045Directionally solidified castings
    • CCHEMISTRY; METALLURGY
    • C30CRYSTAL GROWTH
    • C30BSINGLE-CRYSTAL GROWTH; UNIDIRECTIONAL SOLIDIFICATION OF EUTECTIC MATERIAL OR UNIDIRECTIONAL DEMIXING OF EUTECTOID MATERIAL; REFINING BY ZONE-MELTING OF MATERIAL; PRODUCTION OF A HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; SINGLE CRYSTALS OR HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; AFTER-TREATMENT OF SINGLE CRYSTALS OR A HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; APPARATUS THEREFOR
    • C30B11/00Single-crystal growth by normal freezing or freezing under temperature gradient, e.g. Bridgman-Stockbarger method
    • C30B11/002Crucibles or containers for supporting the melt

Definitions

  • One feature of this invention is the inverted unidirectional solidification of alloys in the mold for the purpose of eliminating the imperfections resulting from the density inversion.
  • Another feature is a mold assembly that makes possible the directional solidification of alloys from top to bottom with a controlled thermal gradient thereby to produce the desired crystalline structure and/or grain growth.
  • FIG. 1 is a vertical-sectional view through a mold construction.
  • FIG. 2 is a horizontal-sectional view along the line 2-2 of FIG. 1.
  • FIG. 3 is a fragmentary view ofa modification.
  • the shell mold construction includes a central-vertical feeder tube connected at the bottom by lateral arms l2 having passages 14 thereon. Atthe outer ends of the arms are vertical mold elements 16 extending parallel and in spaced relation to the feeder tube and having an article-forming cavity 18 therein.
  • This cavity is shown as being the shape of a turbine blade with an airfoil portion 20, a shroud portion 22 at the bottom end and a root portion 24 at the top thereof.
  • the shroud portion communicates through a vertical passage 30 with the horizontal passage 14.
  • the root portion of the article cavity 18 communicates through a helical-crystal selector passage 32 with a growth zone cavity 34.
  • a chill plate 36 is secured to the mold at the top end of the cavity 34, the mold having a flange 38 at this point by which the chill plate is attached.
  • the mold is generally made up of a plurality of vertical mold elements 16 so that a plurality of articles may be cast at one time.
  • the mold may be made with a plurality of supporting feet 40.
  • the mold is made by the usual shellmold technique using a wax or other disposable pattern over which successive layers of mold material are placed and dried, with the finished mold cured by heating at which time the pattern is melted out.
  • the mold When the mold is ready for use, it is placed on a support plate 42 resting on a bed of heat-insulating powered material 44 such as aluminum oxide.
  • the mold is surrounded by a susceptor 46 which in turn is surrounded by vertically spaced induction heating coils 48 and 49 which are selectively energized for controlling the temperature ofthe mold.
  • the susceptor and heaters extend at least from a point above the chill plate to a point substantially below the shroud portion to assure an accurate control ofthe thermal gradient from the chill to the bottom end ofthe vertical passage 30.
  • the central tube is surrounded by a heating coil 50, preferably a resistance coil, and this coil is shielded from the surrounding article-forming portions of the mold by a cylindri' cal shield 52.
  • a graphite sleeve 53 may be positioned within the coil, as shown. The latter and the shield 52 may rest on the lateral arms 12 and the coil may be incorporated in this shield, as shown.
  • a sprue 54 positioned at the top of the tube directs molten alloy into the vertical passage defined by the tube.
  • the entire structure is preferably mounted in a vacuum chamber so that the casting procedure may be done under vacuum or in an inert atmosphere.
  • the assemblage is used for example in producing parts such as turbine blades or vanes which operate in a high-temperature environment under high stress and are thus cast from the so-called super alloys such as described in the VerSnyder U.S. Pat. No. 3,260,505 or the Piearcey U.S. Pat. No. 3,494,709.
  • the article-forming portion of the mold and the adjacent portions thereof are heated to a temperature above the melting temperature of the alloy and the central tube is also raised to this same temperature. A flow of water is maintained through the chill plate so that it is not melted during this heating process.
  • the molten alloy somewhat superheated, for example, about 50 C., is poured into the sprue to fill the mold completely.
  • a suitable vent 56 in the chill plate permits the escape of entrapped gases within the mold to assure complete filling.
  • the power in the lower heater 48 is reduced at a programmed rate determined by the rate of solidification, and is then cut off to permit completion of the solidification. Once the downward solidification in the article-forming portion is complete, heat to the central tube heater is cut off so that the remainder ofthe alloy may solidify.
  • the mold may be adapted for making columnar-grained articles as in the VerSnyder patent.
  • the growth cavity 34' communicates directly with the root portion 24' so that the columnar growth that is started at the chill plate 36' and becomes parallel vertically oriented columnar grains in the growth zone are propagated downwardly through the article-forming portion. Casting of such articles by this inverted solidification process would be used to produce acceptable columnar-grained articles such as turbine blades for use in the highest temperature turbine stages of the engine.
  • the filling step includes filling the mold such that the level of the alloy in the filling cavity is above the chill plate to provide a positive pressure of alloy against the chill plate.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Mechanical Engineering (AREA)
  • Crystallography & Structural Chemistry (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
  • Crystals, And After-Treatments Of Crystals (AREA)
  • Manufacture And Refinement Of Metals (AREA)

Abstract

Unidirectionally solidified castings are produced by inverted solidification using a chill plate at the top of the mold and controlling the temperature gradient to cause solidification to occur from the top downwardly through the mold.

Description

United States Patent Inventors Stephen M. Copley Madison; Anthony l Giamei, New Haven, both of, Conn. Appl. No. 872,562 Filed Oct. 30, 1969 Patented Aug. 10, 1971 Assignee United Aircraft Corporation East Hartford, Conn.
PROCESS OF CASTING WI'l'll DOWNWARD- UNlDllI-ZCTIONAL SOLIDIFICATION 4 Claims, 3 Drawing Figs.
Int. Cl. 822d 25/06 Field of Search" 164/60 Primary Examiner- Robert D. Baldwin Attorney-Charles A. Warren ABSTRACT: Unidirectionally solidified castings are produced by inverted solidification using a chill plate at the top of the mold and controlling the temperature gradient to cause solidification to occur from the top downwardly through the mold.
PROCESS OF CASTING WITH DOWNWARD- UNIDIRECTION AL SOLIDIFICATION BACKGROUND OF THE INVENTION Unidirectionally solidified castings of the columnar-grained type as described in VerSnyder U.S. Pat. No. 3,260,505 and also of the type described in Piearcey, Ser. No. 540,1 l4, filed Feb. 17, 1966, U.S. Pat. No. 3,494,709 and assigned to a common assignee, are generally formed by casting in a mold resting on a chill plate with a control of the thermal gradient to cause a controlled upward movement of the liquid-solid interface from the chill plate upward to the top of the mold. Such castings are generally satisfactory although at times there is a density inversion during solidification that creates imperfections within or on the surface of the castings.
SUMMARY OF INVENTION One feature of this invention is the inverted unidirectional solidification of alloys in the mold for the purpose of eliminating the imperfections resulting from the density inversion. Another feature is a mold assembly that makes possible the directional solidification of alloys from top to bottom with a controlled thermal gradient thereby to produce the desired crystalline structure and/or grain growth.
BRIEF DESCRIPTION OF THE DRAWING FIG. 1 is a vertical-sectional view through a mold construction.
FIG. 2 is a horizontal-sectional view along the line 2-2 of FIG. 1.
FIG. 3 is a fragmentary view ofa modification.
DESCRIPTION OF THE PREFERRED EMBODIMENT The shell mold construction includes a central-vertical feeder tube connected at the bottom by lateral arms l2 having passages 14 thereon. Atthe outer ends of the arms are vertical mold elements 16 extending parallel and in spaced relation to the feeder tube and having an article-forming cavity 18 therein. This cavity is shown as being the shape of a turbine blade with an airfoil portion 20, a shroud portion 22 at the bottom end and a root portion 24 at the top thereof. The shroud portion communicates through a vertical passage 30 with the horizontal passage 14. The root portion of the article cavity 18 communicates through a helical-crystal selector passage 32 with a growth zone cavity 34. A chill plate 36 is secured to the mold at the top end of the cavity 34, the mold having a flange 38 at this point by which the chill plate is attached.
As shown in FIG. 2, the mold is generally made up ofa plurality of vertical mold elements 16 so that a plurality of articles may be cast at one time. The mold may be made with a plurality of supporting feet 40. The mold is made by the usual shellmold technique using a wax or other disposable pattern over which successive layers of mold material are placed and dried, with the finished mold cured by heating at which time the pattern is melted out.
When the mold is ready for use, it is placed on a support plate 42 resting on a bed of heat-insulating powered material 44 such as aluminum oxide. The mold is surrounded by a susceptor 46 which in turn is surrounded by vertically spaced induction heating coils 48 and 49 which are selectively energized for controlling the temperature ofthe mold. The susceptor and heaters extend at least from a point above the chill plate to a point substantially below the shroud portion to assure an accurate control ofthe thermal gradient from the chill to the bottom end ofthe vertical passage 30.
The central tube is surrounded by a heating coil 50, preferably a resistance coil, and this coil is shielded from the surrounding article-forming portions of the mold by a cylindri' cal shield 52. A graphite sleeve 53 may be positioned within the coil, as shown. The latter and the shield 52 may rest on the lateral arms 12 and the coil may be incorporated in this shield, as shown. A sprue 54 positioned at the top of the tube directs molten alloy into the vertical passage defined by the tube. The entire structure is preferably mounted in a vacuum chamber so that the casting procedure may be done under vacuum or in an inert atmosphere.
The assemblage is used for example in producing parts such as turbine blades or vanes which operate in a high-temperature environment under high stress and are thus cast from the so-called super alloys such as described in the VerSnyder U.S. Pat. No. 3,260,505 or the Piearcey U.S. Pat. No. 3,494,709. The article-forming portion of the mold and the adjacent portions thereof are heated to a temperature above the melting temperature of the alloy and the central tube is also raised to this same temperature. A flow of water is maintained through the chill plate so that it is not melted during this heating process. When temperatures are stabilized the molten alloy, somewhat superheated, for example, about 50 C., is poured into the sprue to fill the mold completely. A suitable vent 56 in the chill plate permits the escape of entrapped gases within the mold to assure complete filling.
At the time the mold is filled, solidification of the alloy begins at the water-cooled copper chill plate. Up to this time both induction heating coils 48 and 49 have been energized but as the mold is filled the upper coil 49 is cut off to begin the cooling of the mold from top to bottom. The escape of heat to the chill plate causes the vertically downward growth of columnar grains of alloy in the growth cavity 34 and into the helical passage 32 where a single crystal is selected to continue its growth downwardly into the article-forming cavity thereby forming a single crystal article as described and claimed in Piearcey U.S. Pat. No. 3,494,709.
The maintenance of heat from the resistance coil around the central tube keeps the alloy in this tube molten, and the heat from induction coil 48 keeps the alloy molten in the horizontal passages so that the metal in the central tube maintains a positive hydrostatic pressure on the liquid-solid interface where the alloy is solidifying downwardly in the article cavity. This hydrostatic pressure increases as the liquid-solid interface proceeds downwardly and thus the pressure on the mushy zone increases toward the bottom end of This the article cavity.
As the liquid-solid interface moves downwardly during the casting operation, the power in the lower heater 48 is reduced at a programmed rate determined by the rate of solidification, and is then cut off to permit completion of the solidification. Once the downward solidification in the article-forming portion is complete, heat to the central tube heater is cut off so that the remainder ofthe alloy may solidify.
It has been found that in the usual formation of directionally solidified articles from bottom to top there are liquid jetsof the alloy that flow upwardly within the mushy zone caused by instability resulting from a density inversion in this zone. These jets detrimentally affect the proper solidification of the alloy within the mushy zone. This may result in local areas of segregation trails rich in rejected solute which on the surface of the cast article are referred to as freckles. These trails often contain small randomly oriented grains and are a defect which may make the cast article unacceptable. Such freckles or trails would be eliminated by the inverted solidification above described, since the mushy zone density profile will be stable with respect to the gravitational field.
Referring now to FIG. 3, the mold may be adapted for making columnar-grained articles as in the VerSnyder patent. To accomplish this, the growth cavity 34' communicates directly with the root portion 24' so that the columnar growth that is started at the chill plate 36' and becomes parallel vertically oriented columnar grains in the growth zone are propagated downwardly through the article-forming portion. Casting of such articles by this inverted solidification process would be used to produce acceptable columnar-grained articles such as turbine blades for use in the highest temperature turbine stages of the engine.
We claim:
1. In the production of directionally solidified cast alloy articles, the steps of:
providing a mold having vertically extending filling and article-forming cavities interconnected at the bottoms thereof, both cavities being open at the top ends,
placing a chill plate on the open top end of the article-forming cavity,
heating the mold to a temperature above the melting point of the alloy,
filling the mold with the molten alloy,
gradually reducing the temperature of the article-forming cavity in a direction downwardly from the chill plate to cause directional solidification of the alloy within the artiole-forming cavity in a direction downwardly from the chill plate and,
maintaining the alloy in the filling cavity above the melting temperature until the alloy in the filling cavity is solidified.
2. The process of claim 1 with the added step of resting the mold on a bed of heat-insulating material before the alloy is poured into the mold.
3. The process of claim 1 wherein the filling step includes filling the mold such that the level of the alloy in the filling cavity is above the chill plate to provide a positive pressure of alloy against the chill plate.
4. The process of claim 1 with the added step of providing a plurality of vertically spaced heating coils around the article forming cavity and wherein the step of gradually reducing the temperature includes selectively reducing the heating effect of these coils from top to bottom to produce a thermal gradient from top to bottom of the article cavity during solidification of the alloy.

Claims (4)

1. In the production of directionally solidified cast alloy articles, the steps of: providing a mold having vertically extending filling and article-forming cavities interconnected at the bottoms thereof, both cavities being open at the top ends, placing a chill plate on the open top end of the article-forming cavity, heating the mold to a temperature above the melting point of the alloy, filling the mold with the molten alloy, gradually reducing the temperature of the article-forming cavity in a direction downwardly from the chill plate to cause directional solidification of the alloy within the articleforming cavity in a direction downwardly from the chill plate and, maintaining the alloy in the filling cavity above the melting temperature until the alloy in the filling cavity is solidified.
2. The process of claim 1 with the added step of resting the mold on a bed of heat-insulating material before the alloy is poured into the mold.
3. The process of claim 1 wherein the filling step includes filling the mold such that the level of the alloy in the filling cavity is above the chill plate to provide a positive pressure of alloy against the chill plate.
4. The process of claim 1 with the added step of providing a plurality of vertically spaced heating coils around the article forming cavity and wherein the step of gradually reducing the temperature includes selectively reducing the heating effect of these coils from top to bottom to produce a thermal gradient from top to bottom of the article cavity during solidification of the alloy.
US872562A 1969-10-30 1969-10-30 Process of casting with downward-unidirectional solidification Expired - Lifetime US3598172A (en)

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GB (1) GB1270630A (en)

Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4111252A (en) * 1977-08-01 1978-09-05 United Technologies Corporation Method for making molds and mold components for casting single crystal metallic articles
US4133368A (en) * 1977-08-01 1979-01-09 United Technologies Corporation Single crystal casting mold and method for making same
US4813470A (en) * 1987-11-05 1989-03-21 Allied-Signal Inc. Casting turbine components with integral airfoils
US6435257B2 (en) * 1997-09-19 2002-08-20 Concurrent Technologies Corporation Bottom pouring fully dense long ingots
CN106734907A (en) * 2016-11-25 2017-05-31 中航动力股份有限公司 A kind of directional solidification cylindrulite and single crystal blade casting method
CN107971468A (en) * 2017-12-29 2018-05-01 深圳微纳增材技术有限公司 A kind of crystallizer for being used to refine ingot solidification tissue
CN110465625A (en) * 2019-09-11 2019-11-19 中国科学院金属研究所 A kind of ceramic shell preparation method improving the physics scab of high temperature alloy directional solidification castings
CN111590056A (en) * 2020-05-22 2020-08-28 东方电气集团东方汽轮机有限公司 Casting structure and casting method for directional solidification of high-temperature alloy

Families Citing this family (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE2853162C2 (en) * 1978-12-08 1982-05-19 Vasilij Alekseevič Moskva Čumakov Device for the production of cast parts with directed crystallization
AU654308B2 (en) * 1990-11-05 1994-11-03 Comalco Aluminium Limited Casting of metal objects
BR9107065A (en) * 1990-11-05 1993-09-28 Comalco Alu METAL OBJECTS FOUNDATION
DE19919869B4 (en) 1999-04-30 2009-11-12 Alstom Casting furnace for the production of directionally monocrystalline and polycrystalline solidified casting bodies

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US129699A (en) * 1872-07-23 Improvement in stoppers for steel-ingot molds
FR988645A (en) * 1949-01-10 1951-08-29 Method and means for improving the characteristics of billets
US3376915A (en) * 1964-10-21 1968-04-09 Trw Inc Method for casting high temperature alloys to achieve controlled grain structure and orientation
US3494709A (en) * 1965-05-27 1970-02-10 United Aircraft Corp Single crystal metallic part
US3543284A (en) * 1968-03-20 1970-11-24 United Aircraft Corp Process for casting single crystal shapes

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US129699A (en) * 1872-07-23 Improvement in stoppers for steel-ingot molds
FR988645A (en) * 1949-01-10 1951-08-29 Method and means for improving the characteristics of billets
US3376915A (en) * 1964-10-21 1968-04-09 Trw Inc Method for casting high temperature alloys to achieve controlled grain structure and orientation
US3494709A (en) * 1965-05-27 1970-02-10 United Aircraft Corp Single crystal metallic part
US3543284A (en) * 1968-03-20 1970-11-24 United Aircraft Corp Process for casting single crystal shapes

Cited By (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4111252A (en) * 1977-08-01 1978-09-05 United Technologies Corporation Method for making molds and mold components for casting single crystal metallic articles
US4133368A (en) * 1977-08-01 1979-01-09 United Technologies Corporation Single crystal casting mold and method for making same
US4813470A (en) * 1987-11-05 1989-03-21 Allied-Signal Inc. Casting turbine components with integral airfoils
US6435257B2 (en) * 1997-09-19 2002-08-20 Concurrent Technologies Corporation Bottom pouring fully dense long ingots
US6457512B1 (en) * 1997-09-19 2002-10-01 Concurrent Technologies Corporation Bottom pouring fully dense long ingots
CN106734907A (en) * 2016-11-25 2017-05-31 中航动力股份有限公司 A kind of directional solidification cylindrulite and single crystal blade casting method
CN106734907B (en) * 2016-11-25 2018-11-30 中航动力股份有限公司 A kind of directional solidification cylindrulite and single crystal blade casting method
CN107971468A (en) * 2017-12-29 2018-05-01 深圳微纳增材技术有限公司 A kind of crystallizer for being used to refine ingot solidification tissue
CN110465625A (en) * 2019-09-11 2019-11-19 中国科学院金属研究所 A kind of ceramic shell preparation method improving the physics scab of high temperature alloy directional solidification castings
CN110465625B (en) * 2019-09-11 2021-01-12 中国科学院金属研究所 Preparation method of ceramic shell for improving physical sand adhesion of high-temperature alloy directional solidification casting
CN111590056A (en) * 2020-05-22 2020-08-28 东方电气集团东方汽轮机有限公司 Casting structure and casting method for directional solidification of high-temperature alloy

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FR2100590A1 (en) 1972-03-24
CA930929A (en) 1973-07-31
GB1270630A (en) 1972-04-12
AU2084870A (en) 1972-04-13
DE2053062A1 (en) 1971-05-06

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