US3847203A - Method of casting a directionally solidified article having a varied composition - Google Patents

Method of casting a directionally solidified article having a varied composition Download PDF

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Publication number
US3847203A
US3847203A US00265251A US26525172A US3847203A US 3847203 A US3847203 A US 3847203A US 00265251 A US00265251 A US 00265251A US 26525172 A US26525172 A US 26525172A US 3847203 A US3847203 A US 3847203A
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United States
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mould
alloy
molten alloy
alloys
casting
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US00265251A
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English (en)
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J Northwood
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UK Secretary of State for Defence
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Secr Defence
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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
    • B22D27/15—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting by using vacuum
    • 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

  • ABSTRACT A first molten alloy is poured into a mould and pro gressively cooled to produce a vertical columnar crystal growth. A second molten alloy is then poured in while the surface of the first alloy is still liquid. The progressive cooling is then continued. A suitable mould is made of ceramic material and has an overflow tube formed in the wall of the mould so that any excess of the first alloy will run off. Two pairs of al loys, suitable for casting turbine blades, are described. The advantage of this method is that different parts of the casting can be formed from different alloys and that the known advantages of controlled columnar crystal growth are substantially maintained right across the join.
  • Blades for use in fluid flow machines such as gas turbine engines. These include rotor and stator blades for compressors and turbines, and inlet (or nozzle) guide vanes.
  • the blades comprise two main parts, namely a working portion and a root portion.
  • the working portion normally of aerofoil section, is subjected to impingement by gases and is attached to supporting structure by the root portion.
  • Rotor blades are additionally subjected to centrifugal forces, while turbine blades operate at high temperatures.
  • a gas turbine rotorblade will thus be seen to require a wide combination of properties and these differ between the working portion and the root portion.
  • the working portion of a gas turbine rotor blade needs good stress/rupture strength at elevated tempe ratures, must exhibit a minimum of creep deformation under centrifugal loadings at such temperatures and be resistant to oxidation by hot gases and to the effects of thermal fatigue.
  • the root portion should have good ductility at somewhat lower temperatures, a high tensile strength and be fatigue resistant.
  • the change in section usual between a working portion and a root portion through which bending and vibrational stresses must be transmitted gives rise to stress concentrations which make a low notch sensitivity also desirable.
  • Nickel-base alloys are in general easily cast and intrinsically possess many desirable properties which make them eminently suitable for gas turbine blading. Continuing development has resulted in alloys having high creep strength at the high operating temperatures which have become prevalent. Many of these alloys moreover do not lend themselves to forging.
  • the present invention provides a method of casting a metal article comprising introducing a first molten alloy into a mould having means for progressive cooling of the mould, whereby crystal growth in the molten alloy can be controlled to form a vertical columnar structure, introducing a second molten alloy of compatible nature into the mould while maintaining the surface of the'first alloy in a liquid state and subsequently continuing progressive cooling of the mould.
  • the first and second alloys are nickel-base alloys.
  • the mould may be of ceramic material having a part in contact with a highly conductive cooling surface and with heating elements arranged about the mould so as to vary the axial location at which heat may be applied to the mould, either by relative movement between elements and mould or by selective use of elements.
  • the mould may include an overflow into which excess first molten alloy may flow, the vertical location of the overflow inlet in the mould determining the depth of first molten alloy in the mould and hence the position of the interface between the two alloys.
  • the invention also provides a cast metal article comprising adjacent parts formed of different alloys and having a common columnar crystalline structure.
  • One such article is a turbine blade in which the adjacent parts are respectively a working portion and a root portion.
  • FIG. 1 is an axial section through an assembly of apparatus for metal casting
  • FIG. 2 is an axial section through part of a mould containing molten metal
  • FIG. 3 is an elevation of a turbine blade.
  • FIG. 1 shows a chamber 1 enclosing a crucible 2 and a furnace 3 which in turn encloses a mould 4.
  • the crucible is surrounded by a high frequency induction heating coil 5 and can be raised and tilted by conventional means (not shown) to a pouring position as indicated in dotted lines.
  • the furnace 3, of the well-known electrical resistance type comprises heating elements 6 supported in refractory insulating material surrounding a central axially extending aperture.
  • the furnace is mounted with the central aperture extending vertically (according to the Figure) and the heating elements extend around the aperture as a coil having its windings pitched closer together towards the bottom than higher up, to give greater heating capacity in the lower portion of the furnace.
  • the mould 4 is located centrally within the aperture and is formed of ceramic or other refractory material built up in known manner around a wax pattern which is subsequently burned out during firing of the mould to leave a cavity defining the shape of the article to be cast.
  • the mould which may contain a core if desired, is open-ended and is mounted at its lower end on a chill-plate 7 which also closes the bottom of the mould.
  • the chill-plate 7 comprises a block of metal, preferably copper or a copper alloy, having good thermal conductivity and has an internal cavity through which water can be circulated for cooling by way of pipes 8, 9.
  • the furnace 3 is supported by a platform 10 connected by a die-block 11 to a lead-screw 12.
  • the lead-screw can be driven through gearing 13, 14 by an electric motor (not shown) to raise or lower the furnace 3 relative to the mould 4.
  • an overflow 30 shown in FIG. 2 only
  • the overflow is provided with a U-shaped trap 31 to retain excess first alloy.
  • the chamber 1 is first evacuated by means of a vacuum pump (not shown).
  • the mould 4 is then pre-heated by the furnace 3, which is set at its lowest position, to a temperature in excess of the melting temperature of the metal to be cast, usually 150 to 200C above the alloy liquidus temperature, and cooling water is circulated in the internal cavity of the chill-plate 7 in order to maintain the upper surface of the chill-plate well below the solidification temperature of the metal to be cast.
  • a quantity of metal (a nickel-base alloy, for example) is melted in the crucible 1 by the agency of the heating coil 5.
  • the crucible is then raised and tilted to pour the molten metal into the mould 4 by way of a tundish 15, after which the crucible is restored to its normal position and charged with another metal (e.g. another nickel-base alloy of different composition to that first mentioned), which is melted in turn.
  • another metal e.g. another nickel-base alloy of different composition to that first mentioned
  • Excess first alloy flows into the overflow 30 until the surface of the alloy reaches the bottom of the overflow inlet. Some of the excess first alloy is retained in the overflow trap 31 and solidifies therein on cooling, thereby preventing second molten alloy from flowing through the overflow.
  • the chill-plate 7 extracts heat from the metal in contact with it and solidification commences in this zone.
  • the furnace 3 is slowly raised by rotation of the lead-screw 12 to give progressive cooling of the molten metal whereby solidification proceeds at a solid-liquid front moving up the mould.
  • the furnace is stopped in such a position as will maintain the upper surface of the metal in the mould in liquid state, whereupon the second metal is poured from the crucible to fill the mould completely, after-which the furnace is raised once more to continue the progressive cooling of the mould and its contents.
  • the unidirectional temperature gradient established by the progressive cooling ensures that the solidification process proceeds gradually upwardly from the bottom of the mould. Subsequently the furnace is switched off to permit final cooling.
  • the cast article after removal from the mould will have a columnar crystalline structure in which the crystals are unidirectionally aligned substantially parallel to each other in the direction of the mould axis, individual columnar grains usually comprising more than one dendrite arm.
  • FIG. 2 shows the nature of the crystalline growth concerned, and shows an overflow 30 formed in the mould wall 4.
  • Tongues of skeleton crystal (dendrites) 16 form in the liquid metal at the bottom of the mould 4 as a result of the solidification due to the chill-plate.
  • the temperature gradient induced leads them to grow upwardly in parallel formation towards the top surface 17 of the gradually cooling liquid metal.
  • the growth continues until cooling is arrested prior to pouring of the second metal, the interstices 18 at this stage still containing small amounts of liquid metal.
  • the second metal is introduced.
  • there is mingling between the respective liquids (assuming proper compatibility). with possibly some remelting of the tips of the dendrites. Consequently there is virtually complete fusion between the two metals in the transition zone between them.
  • the composition of the interdcndritic material is partly governed by the amount of liquid present when the second metal is introduced.
  • the extent of the transition zone is governed by this and by the rate of cooling in this particular region and is controllable.
  • the heating of the mould above the pouring temperature of the metal is to prevent random crystallizatin, or nucleation, in advance of the controlled solidification which would otherwise spoil the desired structure of the cast article.
  • the cast article may of course be subjected to subsequent heat treatment so as to improve its physical properties in known manner, or be provided with protective coatings.
  • FIG. 3 A gas turbine rotor blade produced by the process described is shown in FIG. 3.
  • the blade comprises a bulbous root portion 19 by which it can be attached to a rotor disc, a working portion of aerofoil section 2t) and a shroud 21 at the tip of the working portion.
  • the root portion 19 is composed of an alloy having high ductility at the root operating temperature while the working portion 20 is composed of a second alloy having good creep resistance at operating temperatures, some reduction in ductility being acceptable.
  • the transition zone between the two alloys occurs at the junction between the root and working portions as indicated by cross-hatching.
  • the root portion would normally be cast first followed by the working portion in the manner previously set out.
  • the lower part or growth zone of the blade as cast is then machined away to remove random crystal growth. Subsequently, continuous crystals will extend through the root portion, through the working portion and into the shroud to give a parallel columnar structure throughout. Unwanted growth at changes of section can be prevented by the provision of smooth curves at
  • the sequence of operations in the process as previously described is not completely exclusive and may be varied in so far as the invention is not affected.
  • casting can take place in an inert atmosphere, such as argon or helium, rather than in a vaccum: it can even be carried out in air where adverse considerations are not involved.
  • the different metals or alloys can be melted in separate crucibles and instead of physically moving the furnace relative to a mould there can be provided means for selectively energising furnace heating elements so as to vary the position of the main heat- Test-pieces B and D referred to in Table l above were produced by reducing the amount of liquid alloy present when the second alloy was introduced into the mould, thereby producing a narrow interfusion zone ing zone.
  • a tensile test on another test-piece controlled coolmg can be d1spensed w1th at a final 10 from the same casting as test-pieceAat 750C gave the stage. to perm1t the formation of randomly oriented f ll i results; crystals at one end of the cast article where this might be desirable, or unimportant.
  • the metals or alloys used need not both be of the h lsflsilc i s l I same metal base, for example one may be mekel-base. l5 i 71 page! another cobalt base, or another non-base, but 1n all Reduction farea 8.0perccn1 cases, the metals or alloys used (chosen for some specific property or properties in a particular area) must I Clalmfi be properly compatible. They must not, for instance, 1.
  • a method of casting a metal article comprising the form harmful transition compositions likely to give a f O ing Steps: zone of weakness, while the process may be difficult to a In oducing a first molten alloy into a mould having operate if alloys have widely differing melting points.
  • an overflow means until molten alloy overflows (Most nickel-base alloys melt in the range 1,3()0 to into the said overflow means; 1,400C and so are generally suitable in both these reb. progressively cooling the mould to produce conspects.)
  • trolled crystal growth in the form of a vertical co- Castings according to the invention have been manulumnar structure in the molten alloy; factured from nickel-base alloys having the following c.
  • Alloy V for carbon, boron taining the surface of the first alloy in a liquid state; and zirconium are maximum values.
  • Alloys l and V have better ductility and are more d. progressively cooling the mould to produce consuitable for root portions, and Alloys H and IV have trolled growth in the form of a vertical columnar better strength at high temperatures making them apstructure in the second molten alloy.
  • Zirconium H 0.6 Nickel and impurities V li tlance Balance Test-piece A B c D 65 Tempcmure 0 980 980 750 750 3.
  • a method ot castmg a metal article compnsmg the Load (tsi) s a 40 -10 followlng steps: Time P (hr) 530 333 a. introducing a first molten alloy into a mould; Elongation (percent) [5.3 l4.X 9.2 3.4

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Turbine Rotor Nozzle Sealing (AREA)
  • Solid-Phase Diffusion Into Metallic Material Surfaces (AREA)
US00265251A 1971-06-22 1972-06-22 Method of casting a directionally solidified article having a varied composition Expired - Lifetime US3847203A (en)

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GB2912571A GB1374462A (en) 1971-06-22 1971-06-22 Casting of metal articles

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US (1) US3847203A (enExample)
JP (1) JPS5438583B1 (enExample)
CA (1) CA970528A (enExample)
DE (1) DE2230317C2 (enExample)
FR (1) FR2143278B1 (enExample)
GB (1) GB1374462A (enExample)

Cited By (24)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3939895A (en) * 1974-11-18 1976-02-24 General Electric Company Method for casting directionally solidified articles
US3942581A (en) * 1974-11-29 1976-03-09 General Electric Company Method and apparatus for casting directionally solidified articles
US4054171A (en) * 1977-01-13 1977-10-18 Southwire Company Method and apparatus for starting the continuous casting of a metal
US4178986A (en) * 1978-03-31 1979-12-18 General Electric Company Furnace for directional solidification casting
US4573516A (en) * 1979-12-14 1986-03-04 The Secretary Of State For Defence In Her Britannic Majesty's Government Of The United Kingdom Of Great Britain And Northern Ireland Method of and apparatus for casting directionally solidified articles
US4905752A (en) * 1988-03-28 1990-03-06 Pcc Airfoils, Inc. Method of casting a metal article
US5503215A (en) * 1994-05-05 1996-04-02 Leybold Durferrit Gmbh Precision casting system with lock
US5897069A (en) * 1997-08-14 1999-04-27 Zebco Fishing reel frame
US5952113A (en) * 1995-08-08 1999-09-14 Kegulian; Nubar Multi-colored cast jewelry
US6311760B1 (en) * 1999-08-13 2001-11-06 Asea Brown Boveri Ag Method and apparatus for casting directionally solidified article
US6450237B1 (en) 2001-04-02 2002-09-17 Alcoa Inc Compound cast product and method for producing a compound cast product
US20050072546A1 (en) * 2003-10-01 2005-04-07 Loyalty Founder Enterprise Co., Ltd. Sink compound laminate modeling process
US20080096043A1 (en) * 2004-07-27 2008-04-24 Universidade Do Minho Process and Equipment For Obtaining Metal Or Metal Matrix Components With A Varying Chemical Composition Along The Height Of The Component And Components Thus Obtained
EP2210688A1 (de) * 2009-01-21 2010-07-28 Siemens Aktiengesellschaft Bauteil mit unterschiedlichem Gefüge und Verfahren zur Herstellung
US20140037981A1 (en) * 2012-08-03 2014-02-06 General Electric Company Casting methods and molded articles produced therefrom
WO2014133635A2 (en) 2012-12-14 2014-09-04 United Technologies Corporation Hybrid turbine blade for improved engine performance or architecture
GB2515889A (en) * 2013-05-15 2015-01-07 Gen Electric Casting method, cast article, and casting system
US20160158834A1 (en) * 2013-07-31 2016-06-09 United Technologies Corporation Castings and Manufacture Methods
EP2931458A4 (en) * 2012-12-14 2016-07-27 United Technologies Corp MULTIPLE CASTING
CN106734999A (zh) * 2016-12-29 2017-05-31 西安交通大学青岛研究院 一种镍铝金属间化合物锭的真空铸造装置
EP3074159A4 (en) * 2013-11-27 2017-08-02 United Technologies Corporation Method and apparatus for manufacturing a multi-alloy cast structure
US10422228B2 (en) 2016-04-12 2019-09-24 United Technologies Corporation Manufacturing a monolithic component with discrete portions formed of different metals
EP3167978B1 (en) 2015-11-15 2020-03-04 General Electric Company Casting method and article
US20210402463A1 (en) * 2015-10-14 2021-12-30 Aleris Rolled Products Germany Gmbh Method and device for casting metal alloy ingots

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CH641985A5 (de) * 1979-08-16 1984-03-30 Sulzer Ag Verfahren zur herstellung gerichtet erstarrter gussstuecke.
DE3323896A1 (de) * 1983-07-02 1985-01-17 Leybold-Heraeus GmbH, 5000 Köln Verfahren und vorrichtung zum gerichteten erstarren von schmelzen
DE29715846U1 (de) * 1997-09-04 1997-12-11 ALD Vacuum Technologies GmbH, 63526 Erlensee Vorrichtung zum gerichteten Erstarren von Schmelzen
DE10345937B4 (de) * 2003-09-30 2008-02-14 Ald Vacuum Technologies Ag Vorrichtung für den Feinguß von Metallen

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US3394918A (en) * 1966-04-13 1968-07-30 Howmet Corp Bimetallic airfoils
US3549273A (en) * 1967-11-16 1970-12-22 Imp Metal Ind Kynoch Ltd Blade for use in a fluid flow machine
US3532155A (en) * 1967-12-05 1970-10-06 Martin Metals Co Process for producing directionally solidified castings

Cited By (42)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3939895A (en) * 1974-11-18 1976-02-24 General Electric Company Method for casting directionally solidified articles
US3942581A (en) * 1974-11-29 1976-03-09 General Electric Company Method and apparatus for casting directionally solidified articles
US4054171A (en) * 1977-01-13 1977-10-18 Southwire Company Method and apparatus for starting the continuous casting of a metal
US4178986A (en) * 1978-03-31 1979-12-18 General Electric Company Furnace for directional solidification casting
US4573516A (en) * 1979-12-14 1986-03-04 The Secretary Of State For Defence In Her Britannic Majesty's Government Of The United Kingdom Of Great Britain And Northern Ireland Method of and apparatus for casting directionally solidified articles
US4905752A (en) * 1988-03-28 1990-03-06 Pcc Airfoils, Inc. Method of casting a metal article
US5503215A (en) * 1994-05-05 1996-04-02 Leybold Durferrit Gmbh Precision casting system with lock
US5952113A (en) * 1995-08-08 1999-09-14 Kegulian; Nubar Multi-colored cast jewelry
US5897069A (en) * 1997-08-14 1999-04-27 Zebco Fishing reel frame
US6311760B1 (en) * 1999-08-13 2001-11-06 Asea Brown Boveri Ag Method and apparatus for casting directionally solidified article
US6450237B1 (en) 2001-04-02 2002-09-17 Alcoa Inc Compound cast product and method for producing a compound cast product
US20050072546A1 (en) * 2003-10-01 2005-04-07 Loyalty Founder Enterprise Co., Ltd. Sink compound laminate modeling process
US6935405B2 (en) * 2003-10-01 2005-08-30 Loyalty Founder Enterprise Co., Ltd. Sink compound laminate modeling process
US20080096043A1 (en) * 2004-07-27 2008-04-24 Universidade Do Minho Process and Equipment For Obtaining Metal Or Metal Matrix Components With A Varying Chemical Composition Along The Height Of The Component And Components Thus Obtained
EP2210688A1 (de) * 2009-01-21 2010-07-28 Siemens Aktiengesellschaft Bauteil mit unterschiedlichem Gefüge und Verfahren zur Herstellung
WO2010084036A1 (de) * 2009-01-21 2010-07-29 Siemens Aktiengesellschaft Bauteil mit unterschiedlichem gefüge und verfahren zur herstellung
US9475119B2 (en) * 2012-08-03 2016-10-25 General Electric Company Molded articles
US20140037981A1 (en) * 2012-08-03 2014-02-06 General Electric Company Casting methods and molded articles produced therefrom
US10239120B2 (en) * 2012-08-03 2019-03-26 General Electric Company Casting methods and molded articles produced therefrom
US10035185B2 (en) 2012-12-14 2018-07-31 United Technologies Corporation Hybrid turbine blade for improved engine performance or architecture
US10005125B2 (en) 2012-12-14 2018-06-26 United Technologies Corporation Hybrid turbine blade for improved engine performance or architecture
EP2931459A4 (en) * 2012-12-14 2016-07-13 United Technologies Corp HYBRID TURBINE BUCKET FOR IMPROVED ENGINE PERFORMANCE OR ARCHITECTURE
EP2931458A4 (en) * 2012-12-14 2016-07-27 United Technologies Corp MULTIPLE CASTING
EP3513889A1 (en) * 2012-12-14 2019-07-24 United Technologies Corporation Hybrid turbine blade for improved engine performance or architecture
WO2014133635A2 (en) 2012-12-14 2014-09-04 United Technologies Corporation Hybrid turbine blade for improved engine performance or architecture
US11511336B2 (en) 2012-12-14 2022-11-29 Raytheon Technologies Corporation Hybrid turbine blade for improved engine performance or architecture
US9687910B2 (en) 2012-12-14 2017-06-27 United Technologies Corporation Multi-shot casting
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US10456830B2 (en) 2012-12-14 2019-10-29 United Technologies Corporation Multi-shot casting
GB2515889A (en) * 2013-05-15 2015-01-07 Gen Electric Casting method, cast article, and casting system
US9656321B2 (en) 2013-05-15 2017-05-23 General Electric Company Casting method, cast article and casting system
GB2515889B (en) * 2013-05-15 2016-05-25 Gen Electric Casting method
US20160158834A1 (en) * 2013-07-31 2016-06-09 United Technologies Corporation Castings and Manufacture Methods
US9802248B2 (en) * 2013-07-31 2017-10-31 United Technologies Corporation Castings and manufacture methods
US10449605B2 (en) 2013-11-27 2019-10-22 United Technologies Corporation Method and apparatus for manufacturing a multi-alloy cast structure
EP3074159A4 (en) * 2013-11-27 2017-08-02 United Technologies Corporation Method and apparatus for manufacturing a multi-alloy cast structure
US20210402463A1 (en) * 2015-10-14 2021-12-30 Aleris Rolled Products Germany Gmbh Method and device for casting metal alloy ingots
EP3167978B1 (en) 2015-11-15 2020-03-04 General Electric Company Casting method and article
EP3167978B2 (en) † 2015-11-15 2022-12-28 General Electric Company Casting method and article
US10422228B2 (en) 2016-04-12 2019-09-24 United Technologies Corporation Manufacturing a monolithic component with discrete portions formed of different metals
CN106734999B (zh) * 2016-12-29 2018-12-28 宁波泛德压铸有限公司 一种镍铝金属间化合物锭的真空铸造装置
CN106734999A (zh) * 2016-12-29 2017-05-31 西安交通大学青岛研究院 一种镍铝金属间化合物锭的真空铸造装置

Also Published As

Publication number Publication date
DE2230317A1 (de) 1973-01-11
FR2143278B1 (enExample) 1978-09-29
GB1374462A (en) 1974-11-20
DE2230317C2 (de) 1983-01-27
FR2143278A1 (enExample) 1973-02-02
CA970528A (en) 1975-07-08
JPS5438583B1 (enExample) 1979-11-21

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