WO1998032557A1 - INTEGRATED CRUCIBLE AND MOLD FOR LOW COST η-TiAl CASTINGS - Google Patents
INTEGRATED CRUCIBLE AND MOLD FOR LOW COST η-TiAl CASTINGS Download PDFInfo
- Publication number
- WO1998032557A1 WO1998032557A1 PCT/US1998/001672 US9801672W WO9832557A1 WO 1998032557 A1 WO1998032557 A1 WO 1998032557A1 US 9801672 W US9801672 W US 9801672W WO 9832557 A1 WO9832557 A1 WO 9832557A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- pattern
- sleeve
- crucible
- shell
- mold
- Prior art date
Links
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/02—Sand moulds or like moulds for shaped castings
- B22C9/04—Use of lost patterns
Definitions
- the present invention relates generally to crucibles for casting. More particularly, the present invention provides a one piece integrated crucible and invested mold for use in the casting of reactive metals, particularly complex shapes thereof.
- Reactive metals such as titanium or titanium aluminid ⁇ s
- crucibles comprising of alumina, zircon, or silicates which are typically used in casting metals such as iron, nickel or aluminum.
- Turbocharger rotors are typically cast using nickel superalloy which can be easily melted and cast using invested mold having a zircon facecoat and an alumina-silicate crucible attached to the top ofthe mold. Molten titanium aluminide will rapidly react with the alumina-silicate crucible making casting impossible.
- Candidate crucible materials include yttria (Y 2 O 3 ), thoria (ThO 2 ), calcia (CaO) and other exotic rare earth oxides. Thoria is radioactive and suffers from poor thermal shock resistance. For this reason it has not been exploited industrially. However,
- yttria crucibles are very expensive, $50 to $ 100
- the alumina-silicate crucibles used for nickel superalloy castings are less than $ 1. Since titanium and titanium aluminide castings compete with nickel castings in a wide variety of applications, the high cost of yttria crucibles effectively prices titanium and titanium aluminide castings out of the market. This is particularly important for cost sensitive applications, for example automotive applications.
- Calcia is also a potential refractory material for titanium and titanium aluminides due to its thermal stability.
- US Patent No. 4,710,481 to Degawa et. al. discloses melting titanium and titanium alloys in calcia crucibles.
- calcia is highly hydrophilic and spontaneously hydrates in ambient levels of atmospheric moisture. The hydration is accompanied by volume changes which cause cracking and spallation.
- Calcia crucibles can spontaneously crack after only hours of exposure to atmospheric moisture. For this reason calcia is an impractical material for a crucible in commercial, industrial environments.
- the present invention provides a graphite crucible attached directly to the top of an invested mold in the shape of the complex molded part, a turbocharger rotor for the specif i c embodiments disclosed herein, to form an integrated unit.
- a method for producing the integrated crucible and mold is characterized by the steps of attaching an investment pattern to a cylindrical graphite crucible and building an investment mold shell around the pattern and a mating portion of the crucible.
- the mold shell is created by dipping the pattern and crucible mating portion in an inert ceramic facecoa t slurry, allowing the dipcoat layer to partially dry and/or cure, applying a layer of ceramic stucco over the dipcoat and laminating additional layers of dipcoat and stucco to achieve the desired thickness mold shell.
- the embodiment of the invention described in detail subsequently, provides a one piece crucible/mold system suitable for casting a metal part in vacuum at temperatures exceeding 1400°C .
- the method of employing the apparatus of the invention for cas t ing of complex components takes advantage of the rapid melting and casting of the ⁇ -TiAl to
- Carbon is a known contaminant of ⁇ - TiAl. At low levels, i.e. under 2000 ppm (wt%) it is often added to improve creep
- FIG. 1 is a section elevation view of the integrated graphite crucible and invested mold
- FIG. 2 is a pictorial view of an exemplary turbocharger rotor manufacturable from ⁇ -TiAl using the present invention.
- the integral crucible and mold includes a cylindrical graphite sleeve 10 having a bottom 12 adapted to accommodate attachment of a polystyrene invested mold pattern 14 having an attachment runner 15.
- the attachment runner is sealingly attached to the sleeve with wax 16.
- the sleeve is sized to accommodate a desired meitstock billet 17.
- An investment shell 18 is constituted by laminations of a facecoat slurry 20 and ceramic stucco 22 (shown only over a portion of the section for clarity), which extend over and adhere to a bottom mating portion of the graphite sleeve.
- the hardened shell laminate After firing, which results in vaporization of the pattern, the hardened shell laminate is fixedly attached to the graphite sleeve forming an integral crucible and mold for casting of the desired part. .
- An aperture 24 in the bottom face of the sleeve provides a flow path for the molten casting metal into the mold shell while the rim 26 retains the meitstock billet in the crucible in a position for induction heating.
- a method for creating and employing the apparatus of the present invention includes the steps of attaching the polystyrene turbocharger wheel pattern to the cylindrical graphite sleeve by dipping the- top of the polystyrene pattern in hot wax and inserting it into the recess in the bottom of the graphite sleeve.
- An investment shell is next built around the polystyrene pattern and the lower portion of the sleeve.
- the investment mold process begins with dipping the pattern made of wax or plastic having the shape of the desired casting in a facecoat slurry made from any ceramic inert to ⁇ -TiAl, for example, yttria or calcia.
- the crucible/invested mold assembly is then transferred while still hot from the furnace and placed in a casting chamber and evacuated.
- a cylindrical meitstock billet of the casting metal is inserted in the crucible.
- the metal is next rapidly melted by inductively heating the graphite crucible. Since graphite is a strong susceptor, the crucible is quickly heated to the melting temperature of the ⁇ -TiAl.
- the molten metal falls directly into the attached invested mold with the assistance of gravity with a minimum of superheat and hold time.
- the short hold time and low superheat prevents significant contamination by carbon from the crucible.
- the short drop distance attained as a result of the one piece design of the crucible/investment mold, allows full fill in thin sections. Greater drop distances, as would be required by two piece
- the graphite crucible/invested turbocharger mold assembly was then transferred while still hot from the furnace, charged with the casting metal meitstock billet, placed under a quartz bell jar and evacuated.
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Molds, Cores, And Manufacturing Methods Thereof (AREA)
- Golf Clubs (AREA)
- Mold Materials And Core Materials (AREA)
- Physical Vapour Deposition (AREA)
- Nitrogen And Oxygen Or Sulfur-Condensed Heterocyclic Ring Systems (AREA)
- Adornments (AREA)
Priority Applications (6)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
JP53225898A JP2001509083A (ja) | 1997-01-27 | 1998-01-27 | 低価格γ−TiAl鋳造のための統合されたるつぼ及びモールド |
BR9807084-3A BR9807084A (pt) | 1997-01-27 | 1998-01-27 | Processo para a produção de cadinhos e moldes integrados para fundições de metais reativos |
DE69805164T DE69805164T2 (de) | 1997-01-27 | 1998-01-27 | Verfahren zur herstellung eines tiegels mit integriertem form zur preiswerten herstellung von gamma-tial-gussteilen |
AU65336/98A AU6533698A (en) | 1997-01-27 | 1998-01-27 | Integrated crucible and mold for low cost gamma-tial castings |
EP98911363A EP0963262B1 (en) | 1997-01-27 | 1998-01-27 | Method for producing an integrated crucible and mold for low cost gamma-tial castings |
AT98911363T ATE216929T1 (de) | 1997-01-27 | 1998-01-27 | Verfahren zur herstellung eines tiegels mit integriertem form zur preiswerten herstellung von gamma-tial-gussteilen |
Applications Claiming Priority (4)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US3604197P | 1997-01-27 | 1997-01-27 | |
US60/036,041 | 1997-01-27 | ||
US814398A | 1998-01-16 | 1998-01-16 | |
US09/008,143 | 1998-01-16 |
Publications (2)
Publication Number | Publication Date |
---|---|
WO1998032557A1 true WO1998032557A1 (en) | 1998-07-30 |
WO1998032557A9 WO1998032557A9 (en) | 1999-02-04 |
Family
ID=26677855
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/US1998/001672 WO1998032557A1 (en) | 1997-01-27 | 1998-01-27 | INTEGRATED CRUCIBLE AND MOLD FOR LOW COST η-TiAl CASTINGS |
Country Status (9)
Country | Link |
---|---|
EP (1) | EP0963262B1 (zh) |
JP (1) | JP2001509083A (zh) |
CN (1) | CN1101284C (zh) |
AT (1) | ATE216929T1 (zh) |
BR (1) | BR9807084A (zh) |
DE (1) | DE69805164T2 (zh) |
ES (1) | ES2176986T3 (zh) |
PT (1) | PT963262E (zh) |
WO (1) | WO1998032557A1 (zh) |
Cited By (17)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB2369594A (en) * | 2000-10-16 | 2002-06-05 | Howmet Res Corp | Making investment casting molds; heated hopper |
DE10209346A1 (de) * | 2002-03-02 | 2003-09-25 | Daimler Chrysler Ag | Herstellungsverfahren für ein mehrteiliges Ventil für Verbrennungsmotoren |
WO2005025778A1 (en) * | 2003-09-12 | 2005-03-24 | Universidade Do Minho | PROCESS FOR OBTAINING Ϝ-TiAL PIECES BY CASTING |
US7258158B2 (en) | 2004-07-28 | 2007-08-21 | Howmet Corporation | Increasing stability of silica-bearing material |
US7318466B2 (en) * | 2004-05-12 | 2008-01-15 | Snecma Moteurs | Lost wax casting method |
US7370688B2 (en) * | 2004-05-12 | 2008-05-13 | Snecma | Lost wax moulding method with contact layer |
US8048365B2 (en) * | 2007-04-30 | 2011-11-01 | General Electric Company | Crucibles for melting titanium alloys |
US8708033B2 (en) | 2012-08-29 | 2014-04-29 | General Electric Company | Calcium titanate containing mold compositions and methods for casting titanium and titanium aluminide alloys |
US8858697B2 (en) | 2011-10-28 | 2014-10-14 | General Electric Company | Mold compositions |
US8906292B2 (en) | 2012-07-27 | 2014-12-09 | General Electric Company | Crucible and facecoat compositions |
US8932518B2 (en) | 2012-02-29 | 2015-01-13 | General Electric Company | Mold and facecoat compositions |
US8992824B2 (en) | 2012-12-04 | 2015-03-31 | General Electric Company | Crucible and extrinsic facecoat compositions |
US9011205B2 (en) | 2012-02-15 | 2015-04-21 | General Electric Company | Titanium aluminide article with improved surface finish |
US9192983B2 (en) | 2013-11-26 | 2015-11-24 | General Electric Company | Silicon carbide-containing mold and facecoat compositions and methods for casting titanium and titanium aluminide alloys |
US9511417B2 (en) | 2013-11-26 | 2016-12-06 | General Electric Company | Silicon carbide-containing mold and facecoat compositions and methods for casting titanium and titanium aluminide alloys |
US9592548B2 (en) | 2013-01-29 | 2017-03-14 | General Electric Company | Calcium hexaluminate-containing mold and facecoat compositions and methods for casting titanium and titanium aluminide alloys |
US10391547B2 (en) | 2014-06-04 | 2019-08-27 | General Electric Company | Casting mold of grading with silicon carbide |
Families Citing this family (7)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US6663347B2 (en) * | 2001-06-06 | 2003-12-16 | Borgwarner, Inc. | Cast titanium compressor wheel |
DE102009018801A1 (de) | 2009-04-24 | 2009-11-05 | Daimler Ag | Turbolader-Anordnung |
CN101875106B (zh) * | 2009-11-20 | 2011-12-28 | 北京科技大学 | 一种定向凝固高铌钛铝基合金的制备方法 |
CN101984321B (zh) * | 2010-11-23 | 2012-05-23 | 北京科技大学 | 一种钛铝合金定向凝固用坩埚型模的制备方法 |
CN102527936B (zh) * | 2012-01-19 | 2013-04-10 | 沈阳铸造研究所 | 一种用于低膨胀合金精密成形的石墨型铸造方法 |
DE102018109322A1 (de) * | 2018-04-19 | 2019-10-24 | Engel Austria Gmbh | Aufschmelzeinheit für eine Formgebungsmaschine und Formgebungsmaschine |
CN112108641A (zh) * | 2019-06-19 | 2020-12-22 | 中冶宝钢技术服务有限公司 | 用于中间包耐材内衬整体浇注的模芯定位方法 |
Citations (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JPH01157759A (ja) * | 1987-07-25 | 1989-06-21 | Asahi Roentgen Kogyo Kk | チタンまたはチタン合金精密鋳造方法およびその装置 |
-
1998
- 1998-01-27 PT PT98911363T patent/PT963262E/pt unknown
- 1998-01-27 ES ES98911363T patent/ES2176986T3/es not_active Expired - Lifetime
- 1998-01-27 DE DE69805164T patent/DE69805164T2/de not_active Expired - Fee Related
- 1998-01-27 WO PCT/US1998/001672 patent/WO1998032557A1/en active IP Right Grant
- 1998-01-27 EP EP98911363A patent/EP0963262B1/en not_active Expired - Lifetime
- 1998-01-27 AT AT98911363T patent/ATE216929T1/de not_active IP Right Cessation
- 1998-01-27 JP JP53225898A patent/JP2001509083A/ja not_active Ceased
- 1998-01-27 CN CN98802006.8A patent/CN1101284C/zh not_active Expired - Fee Related
- 1998-01-27 BR BR9807084-3A patent/BR9807084A/pt not_active IP Right Cessation
Patent Citations (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JPH01157759A (ja) * | 1987-07-25 | 1989-06-21 | Asahi Roentgen Kogyo Kk | チタンまたはチタン合金精密鋳造方法およびその装置 |
Non-Patent Citations (1)
Title |
---|
PATENT ABSTRACTS OF JAPAN vol. 013, no. 420 (M - 872) 19 September 1989 (1989-09-19) * |
Cited By (23)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB2369594A (en) * | 2000-10-16 | 2002-06-05 | Howmet Res Corp | Making investment casting molds; heated hopper |
US6749006B1 (en) | 2000-10-16 | 2004-06-15 | Howmet Research Corporation | Method of making investment casting molds |
GB2369594B (en) * | 2000-10-16 | 2004-09-22 | Howmet Res Corp | Method of making investment casting molds |
DE10209346A1 (de) * | 2002-03-02 | 2003-09-25 | Daimler Chrysler Ag | Herstellungsverfahren für ein mehrteiliges Ventil für Verbrennungsmotoren |
DE10209346B4 (de) * | 2002-03-02 | 2004-02-19 | Daimlerchrysler Ag | Herstellungsverfahren für ein mehrteiliges Ventil für Verbrennungsmotoren |
US6868814B2 (en) | 2002-03-02 | 2005-03-22 | Daimlerchrysler Ag | Method for manufacturing a multi-part valve for internal combustion engines |
WO2005025778A1 (en) * | 2003-09-12 | 2005-03-24 | Universidade Do Minho | PROCESS FOR OBTAINING Ϝ-TiAL PIECES BY CASTING |
US7318466B2 (en) * | 2004-05-12 | 2008-01-15 | Snecma Moteurs | Lost wax casting method |
US7370688B2 (en) * | 2004-05-12 | 2008-05-13 | Snecma | Lost wax moulding method with contact layer |
US7258158B2 (en) | 2004-07-28 | 2007-08-21 | Howmet Corporation | Increasing stability of silica-bearing material |
US8048365B2 (en) * | 2007-04-30 | 2011-11-01 | General Electric Company | Crucibles for melting titanium alloys |
US8858697B2 (en) | 2011-10-28 | 2014-10-14 | General Electric Company | Mold compositions |
US9011205B2 (en) | 2012-02-15 | 2015-04-21 | General Electric Company | Titanium aluminide article with improved surface finish |
US8932518B2 (en) | 2012-02-29 | 2015-01-13 | General Electric Company | Mold and facecoat compositions |
US9802243B2 (en) | 2012-02-29 | 2017-10-31 | General Electric Company | Methods for casting titanium and titanium aluminide alloys |
US8906292B2 (en) | 2012-07-27 | 2014-12-09 | General Electric Company | Crucible and facecoat compositions |
US8708033B2 (en) | 2012-08-29 | 2014-04-29 | General Electric Company | Calcium titanate containing mold compositions and methods for casting titanium and titanium aluminide alloys |
US8992824B2 (en) | 2012-12-04 | 2015-03-31 | General Electric Company | Crucible and extrinsic facecoat compositions |
US9803923B2 (en) | 2012-12-04 | 2017-10-31 | General Electric Company | Crucible and extrinsic facecoat compositions and methods for melting titanium and titanium aluminide alloys |
US9592548B2 (en) | 2013-01-29 | 2017-03-14 | General Electric Company | Calcium hexaluminate-containing mold and facecoat compositions and methods for casting titanium and titanium aluminide alloys |
US9192983B2 (en) | 2013-11-26 | 2015-11-24 | General Electric Company | Silicon carbide-containing mold and facecoat compositions and methods for casting titanium and titanium aluminide alloys |
US9511417B2 (en) | 2013-11-26 | 2016-12-06 | General Electric Company | Silicon carbide-containing mold and facecoat compositions and methods for casting titanium and titanium aluminide alloys |
US10391547B2 (en) | 2014-06-04 | 2019-08-27 | General Electric Company | Casting mold of grading with silicon carbide |
Also Published As
Publication number | Publication date |
---|---|
JP2001509083A (ja) | 2001-07-10 |
BR9807084A (pt) | 2000-04-18 |
EP0963262B1 (en) | 2002-05-02 |
EP0963262A1 (en) | 1999-12-15 |
DE69805164T2 (de) | 2002-10-31 |
CN1101284C (zh) | 2003-02-12 |
CN1244147A (zh) | 2000-02-09 |
PT963262E (pt) | 2002-09-30 |
DE69805164D1 (de) | 2002-06-06 |
ATE216929T1 (de) | 2002-05-15 |
ES2176986T3 (es) | 2002-12-01 |
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