US3838729A - Method for making a casting of a directionally solidified alloy - Google Patents

Method for making a casting of a directionally solidified alloy Download PDF

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Publication number
US3838729A
US3838729A US00301638A US30163872A US3838729A US 3838729 A US3838729 A US 3838729A US 00301638 A US00301638 A US 00301638A US 30163872 A US30163872 A US 30163872A US 3838729 A US3838729 A US 3838729A
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United States
Prior art keywords
heat
alloy
mold
generating means
heat generating
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Expired - Lifetime
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US00301638A
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English (en)
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B Daigne
F Girard
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Office National dEtudes et de Recherches Aerospatiales ONERA
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Office National dEtudes et de Recherches Aerospatiales ONERA
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Priority to US473365A priority Critical patent/US3886994A/en
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Publication of US3838729A publication Critical patent/US3838729A/en
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D27/00—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting
    • B22D27/04—Influencing the temperature of the metal, e.g. by heating or cooling the mould
    • B22D27/045—Directionally solidified castings

Definitions

  • the device comprises a thin walled mould means for introducing the alloy into the mould having at least one duct and means for maintaining the lower end of the duct at a constant distance from the free surface of the liquid phase, heating means constituted by elements radiating heating energy and facing said free surface, and heat insulating means around the lateral walls of the mould.
  • the present invention concerns a process and a device for casting parts and ingots. In particular, it enables the obtention of high strength alloy ingots in tended to be cut for machining of. parts which structure must be fine, homogeneous and free from micro-flaws such as microscopic voids and micro-scopic shrinkages.
  • the artof the founder-moulder consists in judiciously disposing in the moulds sources of heat (deadheads that are metal reserves as well) and cold sources (coolers in sand moulds, cooled zones in cast iron moulds) in order to control the isotherm distribution and the temperature gradients.
  • the isothermal areas, and consequently the interfaces of solidification remain approximately plane (an essential requirement for obtaining parallel fibers) only if the moulds and parts have small lateral dimensions.
  • care must be taken to maintain within very restricted limits, the rate at which the solidification interface progresses, for example of the order of cm per hour. Consequently, using said processes, it is possible to produce only castings with small transverse dimensions at a very slow rate of production.
  • FIGS. 1, 2 and 3 each representing a diagrammatic crosssection view of different embodiments.
  • FIG. 1 illustrates the simplest form of embodiment of the moulding device according to the invention.
  • the mould l is of a refractory material which is a good heat conductor, for example a molybdenum sheet covered by an appropriate potting, or else alumina externally reinforced with a molybdenum ring. It rests on an alumina block 2, itself disposed on a copper plate 3 which is provided with circular channels through which passes a flow of cooling water supplied by autonomous circuits.
  • Resistances 6 in crown formation for example of tungsten strip are suspended by means of tubes 7 of refractory insulating material from a plate 8 of polished molybdenum, functioning as a heat shield, itself attached to a molybdenum ring 9 bearing against the wall 5.
  • the resistances 6 are supplied by independant electrical power sources.
  • the crucible 10 which is of molybdenum, is vertically moveable. It is movedby a device not represented in the figure.
  • the bottom of the crucible is connected to a calibrated central nozzle 11.
  • the device of FIG-1 is used as follows:
  • Crucible 10 is arranged in its lowest position so that the lower end of nozzle 11 is only a few millimeters from the bottom of mould l.
  • the resistances 6 and the cooling channels of the cold source 3 are powered.
  • crucible 10 is filled with liquid metal which flows at a slow, constant rate through calibrated nozzle 11.
  • crucible 10 is raised progressively so that the nozzle 11 is always flush with the free surface I of the liquid metal within a few millimeters.
  • the combination of the heat source constituted by the resistances 6 and of the cold source constituted by block 2 cooled by plate 3 causes a marked vertical heat flow while the lateral flow is very small owing to the insulating effect of shield 4 and wall 5.
  • the electrical power supplied to resistances 6, the water flow rate of cold source 3 channels and the raising speed of crucible l0 and nozzle 11 are regulated in such a way that the solidification interface f of the casted metal progresses at the same speed as level 1 of the liquid metal.
  • the thickness of the liquid phase is a few millimeters, and the temperature gradient across the solidification interface is uniform over its entire surface and is vertically oriented whatever the transverse dimensions of the mould.
  • the method device according to the invention thus combine the required conditions for obtaining a casting having a fine, ordered structure free from micro-flaws.
  • the device in FIG. 1 does not, however, enable a constant temperature gradient to be obtained in the vicinity of the solidification interface throughout the entire duration of the operation, since the distance between the interface and the heat source constituted by the resistances 6 decreases as casting progresses, while the impedance or heat resistance imposed by the solidified metal to the heat flow going towards the cold source increases at the same time.
  • the device of FIG. 2 enables the obtention of a sharper and more constant temperature gradient than that of FIG. l.lt comprises almost all the elements of FIG. 2, but shield 8 and support 9 are discarded.
  • Crucible 10 and nozzle 11 are integral with a refractory plate 12 which, in addition supports tubes 7 and resistances 6. This arrangement enables the same distance to be maintained between resistances 6, the free surface 1 of the liquid metal and the interface f of solidification throughout casting by means of the upward movement of plate 12.
  • the device of FIG. 2 does, however, enable aluminium alloy ingots having an ordered structure and a height of about 10cm to be obtained.
  • FIG. 3 represents a device according to the invention which enables obtention of ingots of an even greater height and production of refractory alloys with ordered reinforcing phase.
  • the invention enables a constant temperature gradient at the solidification interface to be obtained throughout the entire casting operation, despite the increasing resistance of the solid phase to the heat flow, by providing means to impose to the lower end of said solid phase a variable temperature according to a law of the following kind.
  • T being the temperature of the lower end of the ingot
  • the invention thus allows for the fact that the temperature T of the lower end of the solid phase must varyv in inverse proportion to the height H to preserve a constant gradient G.
  • the invention provides different constructive solutions meeting this requirement while ensuring evacuation of the heat flow through this liquid and solid phases, for example:
  • variable heat resistance for example a liquid layer of variable thickness
  • the device in FIG. 3 shows different embodiments in the system supplying the bath, and in the system heating the bath, which is an inductor 18.
  • the alloy is supplied in the form of a strip or wire 13 driven and guided by rollers 14 integral with plate 12 and it is fed by a storage reel not represented in the figure. It is pushed towards the bath through a nozzle 15 and, on passing through, is progressively heated by resistances 16 which bring it close to the melting point temperature. Melting induced by the radiation of surface I of the bath.
  • the water circulation channels are here made by machining the upper surface of the plate 3 on which block 2 is brazed.
  • Tungsten strip heating resistances 17 are set in the upper face of block 2 and are in contact with mould 1.
  • a refractory wall 18 in which are set tungsten strip resistances 19.
  • the device in FIG. 3 allows the obtention of a temperature gradient in the vicinity of the solidification interface that is substantially constant and uniform throughout the entire duration of the casting operation.
  • lateral heat losses may be completely eliminated by judiciously adjusting heating of wall 19;
  • the increased heat resistance of the solid portion 5 of the alloy may be compensated for by reducing the temperature of resistances 17 as solidification progresses,
  • the block 2 is 99.5 percent alumina and is 25 mm thick.
  • the cooling water is at a temperature of C.
  • the temperature of the heat source resistances 6 is adjusted so that they are brought to 2,250C and calculation shows that the heat flow through the bath is about 30 W/cm During solidification, the temperature of resistances 17 will be decreased progressively from l,350C to 350C.
  • the device in FIG. 3 enables the production of castings or ingots of refractory alloys, with an ordered reinforcing phase, the size of which may reach 150 mm and the diameter 200 mm or more.
  • the invention may comprise arrangements other than those illustrated in the given examples.
  • the alloy may be brought to the surface of the bath not only in a liquid form or in the form of a wire or strip, but also as a powder.
  • the bath may be heated not only by radiant resistantes, but also by induction or electron flow.
  • the material with a variable heat transmission coefficient constituting block 2 of FIG. 3 may be made of alumina but also, for example, of beryllium oxide.
  • the alloy may be supplied to the mould by means of several lines 11 or nozzles 15 judiciously distributed.
  • a method for making a casting of a directionally solidified alloy comprising the steps of mounting a mold on a chill plate, positioning around said mold a lateral heat insulating structure to limit trans-verse heat transfer, melting an alloy material, supplying the alloy material to the mold through delivering means while continually cooling the chill plate to remove heat from the melted alloy so as to solidify the same from the chill plate upwardly, continuously supplying melted alloy material at a rate substantially equal to its rate of solidification while keeping the outlet of said delivering means at substantially the free level of the liquid alloy in said mold, and continuously heating said liquid in the mold by heat generating means facing said liquid free level and extending over a substantial portion thereof.
  • a method according to claim 1 further comprising the step of continuously displacing the heat generating means away from the chill plate whereby substantially the same spacing between said heat generating means and said liquid free level is maintained during the entire casting operation.
  • a method according to claim 1 wherein said melting of the alloy material is conducted in the vicinity of said delivering mean outlet by additional heat generating means and by the heat radiating from the liquid alloy in said mold.
  • a method according to claim 1 further comprising the steps of providing adjustable heat transfer means between said chill plate and said mold, and of controlling said adjustable heat transfer means according to a predetermined law.
  • T is the temperature at the lower part of the casting
  • T is the temperature of solidification of the alloy
  • C(T) is the thermal conductivity of the solid phase-at temperature T
  • C is the thermal conductivity of the liquid phase in the vicinity of the solidification interface
  • G is the temperature gradient in the liquid phase in the vicinity interface
  • H is the height of the solid phase.
  • thermo resistor means thetherrnal resistance of which decreases as a function of the temperature.
  • thermal resistor means comprise a block of alumina.
  • thermal resistor means comprise a block of berylium oxide.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Continuous Casting (AREA)
US00301638A 1971-11-05 1972-10-27 Method for making a casting of a directionally solidified alloy Expired - Lifetime US3838729A (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
US473365A US3886994A (en) 1971-11-05 1974-05-28 Device for making a casting of a directionally solidified alloy

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
FR7139703A FR2158138B1 (enrdf_load_stackoverflow) 1971-11-05 1971-11-05

Publications (1)

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US3838729A true US3838729A (en) 1974-10-01

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US (1) US3838729A (enrdf_load_stackoverflow)
JP (1) JPS518854B2 (enrdf_load_stackoverflow)
CA (1) CA975923A (enrdf_load_stackoverflow)
CH (1) CH560083A5 (enrdf_load_stackoverflow)
DE (1) DE2252548C3 (enrdf_load_stackoverflow)
FR (1) FR2158138B1 (enrdf_load_stackoverflow)
GB (1) GB1415166A (enrdf_load_stackoverflow)
IT (1) IT970219B (enrdf_load_stackoverflow)
SE (1) SE396562B (enrdf_load_stackoverflow)

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4612023A (en) * 1982-07-15 1986-09-16 Heraeus Quarzschmelze Gmbh Method of manufacturing stria-free, bubble-free and homogeneous quartz-glass plates
US5535812A (en) * 1995-01-06 1996-07-16 Singleton Technology, Inc. Method of and apparatus for continuous casting of metal
US20020170700A1 (en) * 2000-09-01 2002-11-21 Shigeru Yanagimoto Metal-casting method and apparatus, casting system and cast-forging system
US20030221810A1 (en) * 2002-04-26 2003-12-04 Schlienger Max Eric Heating to control solidification of cast structure
US20080083249A1 (en) * 2006-10-10 2008-04-10 Ohara Inc. Method for producing glass and device for shaping glass
US20080257517A1 (en) * 2005-12-16 2008-10-23 General Electric Company Mold assembly for use in a liquid metal cooled directional solidification furnace
EP2730350A3 (en) * 2011-04-01 2017-03-22 IKOI S.r.l. Machine for forming metal bars.

Families Citing this family (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS51145427A (en) * 1975-06-10 1976-12-14 Toho Zinc Co Ltd Method of casting large zinc block
JPS53146259U (enrdf_load_stackoverflow) * 1977-04-25 1978-11-17
DE3323896A1 (de) * 1983-07-02 1985-01-17 Leybold-Heraeus GmbH, 5000 Köln Verfahren und vorrichtung zum gerichteten erstarren von schmelzen
JPH0714550B2 (ja) * 1985-03-20 1995-02-22 ワイケイケイアーキテクチュラルプロダクツ株式会社 鋳造用鋳込装置
WO1999003621A1 (de) * 1997-07-16 1999-01-28 Ald Vacuum Technologies Gmbh Verfahren und vorrichtung zur herstellung von werkstücken oder blöcken aus schmelzbaren materialien
DE29715846U1 (de) * 1997-09-04 1997-12-11 ALD Vacuum Technologies GmbH, 63526 Erlensee Vorrichtung zum gerichteten Erstarren von Schmelzen
DE19934940C2 (de) * 1999-07-26 2001-12-13 Ald Vacuum Techn Ag Vorrichtung zum Herstellen von gerichtet erstarrten Blöcken und Betriebsverfahren hierfür
DE102008051492A1 (de) * 2008-10-13 2010-04-15 Pva Tepla Ag Vorrichtung zum Kristallisieren von Nicht-Eisen-Metallen

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US901361A (en) * 1907-08-02 1908-10-20 George O Eaton Molding process.
US1042092A (en) * 1910-06-03 1912-10-22 Custer Sandless Casting Company Art of casting steel.
US3405220A (en) * 1965-07-16 1968-10-08 United Aircraft Corp Induction electric mold heater
US3620288A (en) * 1969-06-27 1971-11-16 United Aircraft Corp Directionally solidified castings

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US901361A (en) * 1907-08-02 1908-10-20 George O Eaton Molding process.
US1042092A (en) * 1910-06-03 1912-10-22 Custer Sandless Casting Company Art of casting steel.
US3405220A (en) * 1965-07-16 1968-10-08 United Aircraft Corp Induction electric mold heater
US3620288A (en) * 1969-06-27 1971-11-16 United Aircraft Corp Directionally solidified castings

Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4612023A (en) * 1982-07-15 1986-09-16 Heraeus Quarzschmelze Gmbh Method of manufacturing stria-free, bubble-free and homogeneous quartz-glass plates
US5535812A (en) * 1995-01-06 1996-07-16 Singleton Technology, Inc. Method of and apparatus for continuous casting of metal
US20020170700A1 (en) * 2000-09-01 2002-11-21 Shigeru Yanagimoto Metal-casting method and apparatus, casting system and cast-forging system
US20030221810A1 (en) * 2002-04-26 2003-12-04 Schlienger Max Eric Heating to control solidification of cast structure
US6837299B2 (en) 2002-04-26 2005-01-04 Sky+Ltd. Heating to control solidification of cast structure
US20080257517A1 (en) * 2005-12-16 2008-10-23 General Electric Company Mold assembly for use in a liquid metal cooled directional solidification furnace
US20080083249A1 (en) * 2006-10-10 2008-04-10 Ohara Inc. Method for producing glass and device for shaping glass
EP2730350A3 (en) * 2011-04-01 2017-03-22 IKOI S.r.l. Machine for forming metal bars.

Also Published As

Publication number Publication date
JPS4855130A (enrdf_load_stackoverflow) 1973-08-02
FR2158138B1 (enrdf_load_stackoverflow) 1974-11-15
FR2158138A1 (enrdf_load_stackoverflow) 1973-06-15
SE396562B (sv) 1977-09-26
CH560083A5 (enrdf_load_stackoverflow) 1975-03-27
GB1415166A (en) 1975-11-26
DE2252548B2 (de) 1974-12-19
DE2252548C3 (de) 1975-08-07
CA975923A (en) 1975-10-14
IT970219B (it) 1974-04-10
DE2252548A1 (de) 1973-05-10
JPS518854B2 (enrdf_load_stackoverflow) 1976-03-22

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