WO1999013137A1

WO1999013137A1 - Apparatus for producing castings with directional and single crystal structure

Info

Publication number: WO1999013137A1
Application number: PCT/US1998/019020
Authority: WO
Inventors: Vegeny Nikolaevich Kablov; Viktor Vladimirovich Gerasimov; Joseph Markovich Demonis; Elena Mikhailovna Visik
Original assignee: General Electric Company; All-Russian Scientific-Research Institute Of Aviation Materials
Priority date: 1997-09-12
Filing date: 1998-09-14
Publication date: 1999-03-18
Also published as: EP0972093A1; RU2116867C1

Abstract

The present invention relates to metal casting and can be used in producing large sized blades with directional and single crystal structure having large horizontal shoulders. The apparatus comprises a vacuum chamber inside which there is positioned a mold preheating furnace (4) with a ceramic mold (1) and a vertical shield (2) disposed therein, and a crystallizer (7). The shield (2) is positioned concentrically to the casting vertical axis and is fixed on the mold upper portion or on a hanger. The shield (2) can be made integral or as a row of members having projecting flanges which telescopically insert into each other. The shield (2) is made of a graphitized foil or a carbon/carbon based composite material. The disclosed apparatus allows to decrease the role of the radial component of the thermal gradient in the process of directional solidification of the blades having large horizontal shoulders, to increase the degree of structural perfection along the complete height of a casting and to avoid porosity in the transition portion between a shroud and an airfoil.

Description

APPARATUS FOR PRODUCING

CASTINGS WITH DIRECTIONAL AND

SINGLE CRYSTAL STRUCTURE

FIELD OF THE INVENTION

The present invention relates to metal casting and can be used in producing large sized blades with directional and single crystal structure having large horizontal shoulders

Apparatuses for casting blades by directional solidification methods are known Such apparatuses include a heating zone and a cooling zone, which are separated by a horizontal shield or baffle In instances where a chill plate acts as a cooling zone, then a rigid baffle is used as a rule, as described in U S Patent Nos 3,680,028 and 4,763,716, UK Patent Application Nos 1 ,285,319 and 1,562,368, and EP 0589508, Patentschπft 4022389 When cooling is performed by a liquid metal bath, then, besides the rigid baffle, one can use a baffle floating on the surface of the coolant (see German Patent 4,321 ,640, PCT Application 096/05006, Russian Federation Patent 1 ,401 ,715)

The horizontal shields or baffles create a heat barrier between the heating zone and the cooling zone in the apparatuses in order to increase the thermal gradient at the crystal growth front of the cast article (the blade) But when it is necessary to produce blades having large horizontal shoulders, the construction of said shields or baffles should correspond to the maximum size of a blade in a horizontal direction, which decreases the shielding effect and does not ensure the desired crystal structure

The closest to the present invention is the apparatus disclosed in UK Patent Application No 1 ,303,038 being accepted as a prototype The prototype apparatus consists of a vacuum chamber, inside which a furnace for mold preheating is disposed. Disposed inside the furnace is a ceramic cluster of several blades being positioned on a chill plate. Placed between the cluster central part and a casting cavity is a closed shield which has the shape of a circular cavity . Said shield is produced jointly with a ceramic mold, is rigidly connected with it and assists in uniform heating of all the castings in a cluster along its height and also assists in decreasing the mutual effect of the ceramic cluster on the cooling process.

All the above mentioned apparatuses with shields or baffles, including the prototype apparatus, in the process of lowering the mold into the cooling zone from the heating zone, do not decrease the radial component of the thermal gradient and are not acceptable for casting blades with large horizontal shoulders. As a result structural defects and increased porosity in the transition portion of the blade between the shroud and an airfoil are caused.

SUMMARY OF THE INVENTION

The technical task of the present invention is to improve the structure of the casting (i.e., the absence of high and low angle grain boundaries) due to decreasing the radial component of the thermal gradient without changing the temperature axial gradient value in the course of the solidification process. Another aim of the invention is also to improve the yield of single crystal structure in the blade. To achieve this task, the inventive apparatus comprises a vacuum chamber inside which there is positioned a mold preheating furnace with a ceramic mold and a vertical shield disposed therein, and a crystallizer (cooling zone). The vertical shield is made separate from the ceramic mold and is positioned concentrically to the casting's vertical axis; its lower butt end is open and faces the crystallizer. The shield can be made integral of thin graphitized foil having graphite bushes on the butt ends, or can be made as a row of members having projecting flanges which telescopically insert into each other. The number and the height of these members are defined constructively and are dependent on blade sizes. The shield is fixed on the mold upper portion or on a mold hanger. The shield should be made of a heat insulative material such as, but not limited to, graphitized foil, layers of graphite with felt, and composite materials based on carbon/ carbon.

BRIEF DESCRIPTION OF THE DRAWINGS

Fig. la is a schematic representation of the apparatus for casting the blades with large horizontal shoulders, and the shield being opened from the bottom, where the following parts are shown: a ceramic mold (1) for blades, a vertical shield (2), a hanger (3) for molds, a mold preheating furnace (4), furnace insulation (5), a cup for melt pouring (6) and the liquid metal crystallizer (7).

Fig. lb shows the shield being made of the members telescopically inserting into each other.

Fig. 2a illustrates the conventional technique for casting the blades with directional and single crystal structure.

Fig. 2b illustrates how the cluster of the blades is cooled according to the prototype method where the shield construction prevents heating up the blades from inside of the cluster, but doesn't prevent overheating of the transition portion between the shroud and the airfoil.

Fig. 2c illustrates the cooling scheme of a blade having large horizontal shoulders when directional solidification is performed using the liquid metal crystallizer and the inventive vertical shield.

DESCRIPTION OF THE INVENTION

The apparatus works as follows: the mold 1 is surrounded by the vertical shield 2 which is opened from the bottom. The hanger 3 holds the mold in the preheating furnace 4 being embraced by the heat insulation 5. Once the desired temperature has been achieved, the molten superalloy is poured into the mold through the cup 6. After that, the mold is immersed into the liquid metal crystallizer 7 at the predetermined rate. When the blade dimensions are not large, the shield can be made integral of thin graphitized foil having graphite bushes on the butt ends. When the blade dimensions are large, the shield can be made as a row of members, e.g., rings telescopically inserting into each other in the course of directional solidification. As a result, the shield usage efficiency is increased and it is convenient in service. To produce the blades having single crystal structure, the seed with the desired crystallographic orientation is placed inside the mold before the molten alloy is poured into the mold.

In the directional solidification process the vertical shield in the gap between the preheating furnace and the liquid metal coolant level, serves to prevent heat losses in a radial direction and simultaneously does not allow the horizontal shoulders to receive the additional heat flow from the heater while not interrupting the coolant's influence. This helps to provide strict unidirectional axial heat removal from a solidifying casting and also enables avoiding the porosity in the transition portion between a shroud and an airfoil.

Fig. 2a illustrates the conventional technique for casting the blades with directional and single crystal structure. In such a case the cooling of a cluster is effective only over the cluster's periphery but inside the article can be still heated from above.

Fig. 2b illustrates how the cluster of the blades is cooled according to the prototype method; the shield construction prevents heating up the blades from inside of the cluster, but doesn't prevent overheating of the transition portion between a shroud and an airfoil. That is why the blade has defects in its structure. Fig. 2c Illustrates the cooling scheme of a blade having large horizontal shoulders when directional solidification is performed using the liquid metal crystallizer and the suggested vertical shield. The shield acts during the complete process of mold immersion, and the degree of perfection is preserved along the complete height of the structure due to the fact that the suggested apparatus provides the directional solidification without the radial component of the heat flow which has been the main reason for causing the low angle grain boundaries.

The disclosed apparatus allows to decrease the role of the radial component of the thermal gradient in the process of directional solidification of the blades having large horizontal shoulders, to increase the degree of structural perfection along the complete height of a casting, to avoid porosity in the transition portion between a shroud and an airfoil, and to improve the yield of single crystal structure by 10-20%.

Said vertical shield can be used in the installations with both a liquid metal crystallizer and a conventional crystallizer (a chill plate).

Claims

What is claimed:

1. An apparatus for producing castings with directional and single crystal structure, comprising a vacuum chamber inside which there is positioned a mold preheating furnace (4) with a ceramic mold (1) and a vertical shield (2) disposed therein, and a crystallizer (7); said apparatus being characterized in that the vertical shield (2) is made separate from the ceramic mold (1) and is positioned concentrically to the casting vertical axis; its lower butt end is open and faces the crystallizer (7).

2. The apparatus of claim 1 characterized in that the shield (2) is made of a row of members telescopically inserting into each other in the directional solidification process.

3. The apparatus of claim 1 where the shield (2) has graphite bushes on butt ends.

4. The apparatus of claim 1 characterized in that the shield (2) is made of a heat insulative material selected from the group consisting of graphite foil, layers of graphite with felt between the graphite, a composite material based on carbon/carbon and mixtures thereof.

5. A method of making a directional or single crystal structure blade comprising the steps of melting an alloy, pouring the alloy from a cup (6) into a heated mold (1) being surrounded by a vertical shield (2), lowering the mold (1) into a crystallizer (7) at a predetermined rate to produce a directional or single crystal structure in the blade.

6. An article made according to the method of claim 5.

7. An article according to claim 6 with reduced low angle grain boundaries.