WO2013102127A2 - Filtre - Google Patents

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Publication number
WO2013102127A2
WO2013102127A2 PCT/US2012/072148 US2012072148W WO2013102127A2 WO 2013102127 A2 WO2013102127 A2 WO 2013102127A2 US 2012072148 W US2012072148 W US 2012072148W WO 2013102127 A2 WO2013102127 A2 WO 2013102127A2
Authority
WO
WIPO (PCT)
Prior art keywords
filter
contaminant
pathway
passage
impurity
Prior art date
Application number
PCT/US2012/072148
Other languages
English (en)
Other versions
WO2013102127A3 (fr
Inventor
Max Eric Schlienger
Michael Christopher Maguire
Michael Dean Baldwin
Original Assignee
Rolls-Royce Corporation
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Rolls-Royce Corporation filed Critical Rolls-Royce Corporation
Publication of WO2013102127A2 publication Critical patent/WO2013102127A2/fr
Publication of WO2013102127A3 publication Critical patent/WO2013102127A3/fr

Links

Classifications

    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
    • C22B9/00—General processes of refining or remelting of metals; Apparatus for electroslag or arc remelting of metals
    • C22B9/02—Refining by liquating, filtering, centrifuging, distilling, or supersonic wave action including acoustic waves
    • C22B9/023—By filtering
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00—Technologies related to metal processing
    • Y02P10/20—Recycling

Definitions

  • the present invention generally relates to filtering, and more particularly, but not exclusively, to filtering of molten metal.
  • One embodiment of the present invention is a unique filter.
  • Other embodiments include apparatuses, systems, devices, hardware, methods, and combinations for filtering a range of contaminants. Further embodiments, forms, features, aspects, benefits, and advantages of the present application shall become apparent from the description and figures provided herewith.
  • FIG. 1 depicts one embodiment of a filter and containing and receptacles.
  • Fig. 2 depicts one embodiment of a filter.
  • Fig. 3a depicts one embodiment of a filter.
  • Fig. 3b depicts one embodiment of a filter.
  • Fig. 4 depicts one embodiment of a filter.
  • Fig. 5 depicts one embodiment of a filter.
  • Fig. 6 depicts one embodiment of a filter.
  • a liquid containing receptacle 50 for enclosing a liquid 52 is shown in schematic form, and a filter 54 and is shown through which the liquid 52 may pass from the liquid containing receptacle 50 to a receiving receptacle 56.
  • the liquid containing receptacle 50 can be used to house the liquid 52 before it is filtered and includes at least one side 58 that define a space 60 for containing the liquid 52.
  • the at least one side 58 can include one or more surfaces that define the space 60.
  • the liquid containing receptacle 50 can resemble a bowl that in one embodiment might only have a single inside surface, or can include multiple sides as in a boxlike container. In operation the liquid 52 can be either poured into the liquid containing receptacle 50 or can be melted within.
  • the receiving receptacle 56 can be the final destination for the liquid 52 or can be an intermediate destination.
  • the receiving receptacle 56 is a mold useful for receiving the liquid 52 before being cooled into a shaped solid form.
  • the mold can be an investment casting mold used to receive a molten metal.
  • the receiving receptacle 56 can be a ceramic mold produced using free form fabrication techniques and shaped to form a gas turbine engine component part such as a blade or vane when liquid poured from liquid containing receptacle 50 is cooled within the mold. Such a component can be used in gas turbine engines used to power aircraft.
  • the term "aircraft” includes, but is not limited to, helicopters, airplanes, unmanned space vehicles, fixed wing vehicles, variable wing vehicles, rotary wing vehicles, unmanned combat aerial vehicles, tailless aircraft, hover crafts, and other airborne and/or extraterrestrial (spacecraft) vehicles.
  • the receiving receptacle 56 can be utilized in other applications that may not be coupled with an aircraft such as, for example, industrial applications, power generation, pumping sets, naval propulsion, weapon systems, security systems, perimeter defense/security systems, and the like known to one of ordinary skill in the art.
  • the filter 54 is useful to discourage a contaminant within the liquid 52 from exiting the liquid containing receptacle 50 and entering the receiving receptacle 56.
  • the filter can be used to impede and/or capture the contaminant that can either be permanent or temporary.
  • the contaminant can be anything that is not desired in the final cast product, or not permitted to pass by operation of the filter 54.
  • the filter 54 can discourage passage of contaminants through a number of mechanisms including physical interference, surface tension, and van der Walls forces, among potential others. In some forms as will be discussed below the filter 54 can be configured to produce an amount of turbulence to improve filtering.
  • the filter 54 is coupled with the liquid containing receptacle 50 and is positioned to filter at least part of the liquid 52 before the liquid 52 is discharged from the liquid containing receptacle 50. Though only one filter 54 is depicted, in some embodiments the liquid containing receptacle 50 may include more than one.
  • the filter 54 can be glued into the liquid containing receptacle 50, but other techniques of attachment can also be used. In some forms the filter 54 may simply be placed within the liquid containing receptacle 50 without the use of mechanical or chemical fasteners, among other devices. In some applications the filter 54 can be replaced after a single use, but in other applications the filter 54 can be used for multiple pours of the liquid 52.
  • the filter 54 can take a variety of forms.
  • the filter 54 can be used with a vast variety of melt materials including, but not limited to, metals and intermetallic materials.
  • metal in association with the melt and supporting structure it is contemplated herein that the term metal includes elemental metal, alloys, superalloys and intermetallic materials unless specifically provided to the contrary.
  • the filter 54 can be used in single crystal casting operations.
  • the filter 54 can be formed using a variety of techniques, and in on example is formed using free form fabrication techniques.
  • the filter 54 is produced using laser stereolithography in which a number of layers are sequentially constructed. In one form the laser
  • stereolithography produces a filter by activating a photosensitive monomer binder in which is suspended a number of particles to harden the binder and form a green article. After activation the binder can be removed from the green article using techniques such as thermal processing. After removal of the binder the article can be further processed to harden into a finished article. Any number of techniques other than laser stereolithography can be used to create the filter 54.
  • the filter 54 generally includes a number of passages 62 through which the liquid 52 is capable of passing.
  • the passages 62 can be internal to the filter 54 in some embodiments and in other embodiments may include portions formed between the filter 54 and structure coupled to the liquid containing receptacle 50, such as a side of a nozzle (not shown).
  • the passages 62 of the filter 54 can include a portion or portions having a size that discourages passage of a contaminant, whether solid or liquid.
  • the passages 62 can include a cross section that is smaller than a size of a contaminant, thus discouraging the passage of the contaminant through the filter 54.
  • the passages 62 need not be uniform and need not have consistent shapes, though in some embodiments the passages 62 may be either or both uniform and consistent in shape.
  • the filter 54 can include one or more pores that can be interposed between an upstream side and a downstream side of the filter.
  • the one or more pores can form the passage, or a part thereof.
  • In some embodiments of the multiple pores can be interconnected to form one or more tortuous passages between the upstream side and downstream side of the filter 54.
  • the pores can take on any variety of shapes and sizes and can, but need not be, a well defined body bounded by regular geometric shapes. To set forth just one non-limiting example, in some forms the pores can take on an open cell form that includes relatively open rounded shapes interconnected to other pores and/or conduits.
  • the pores can be substantially uniform in characteristics such as size and shape, but in other embodiments the pores can have variations. For example, some pore sizes can be relatively small while other pore sizes are relatively large. As discussed immediately above, the pathway, including any pores that may be present, can have a relatively small cross section such that a contaminant is discouraged from progressing further through the filter. In some forms of the filter, the passages and/or pores can be graded. For example, the filter may have relatively large passages at an upstream end and relatively small passages at a downstream end. In another non-limiting example, the passage sizes can randomly vary throughout the filter 54.
  • pores can be arranged such that the pore size varies continuously from one end to the other, while in some embodiments the pores of similar sizes can be arranged at common stations between ends of the filter. Any number of sizes can be used within the filter and any variety of combination of sizes is contemplated.
  • a number of ligaments 64 are depicted as being interconnected and forming the passages 62.
  • the ligaments 64 depicted in the figure include a number that are arranged in generally the same direction in a given level and that are also arranged at an angle relative to ligaments 64 in an adjacent level.
  • the ligaments 64 in one level can be connected to ligaments 64 in another level at their intersections.
  • the ligaments 64 between the levels can be arranged at right angles to one another or at any other angle. Orientations of the ligaments 64 other than in parallel arrangement within a level of ligaments 64 can be had in other embodiments.
  • ligaments 64 in one level can be arranged to intersect in a cross hatched pattern such as a tic-tac-toe board, with adjacent level having a similar cross hatched pattern but otherwise clocked at an angle relative to an adjacent level.
  • the ligaments 64 themselves need not be arranged in a straight line but rather can take on any variety of other shapes, whether a defined geometric shape or otherwise.
  • the ligaments 64 can extend fully from one edge of the filter 54 to another or can be interconnected with other ligaments intermediate the sides/ends of the filter 54. In short, any variety of ligament 64 arrangements are contemplated herein.
  • the surface of the passage 62, and/or the ligaments 64 defining the passage 62 can be formed such that a texture of the surface is non-smooth and rather includes a number of edges capable of discouraging movement of contaminants though the filter 54.
  • the nature of the surface of the passage 62, and/or the ligaments 64 defining the passage 62 can vary throughout the filter 54 such that a variety and/or range of contaminant is discouraged from flowing through the filter. Such a variation can be graded or can be randomly distributed throughout the filter 54. Various arrangements of the surface and texture are discussed further below.
  • the layers 66 that make up the surface of the passage 62 can have a variety of dimensions which can include a variety of locations to which the layers 66 extend.
  • the layers 66 can extend in the same general direction as the ligaments 64 in the embodiments discussed above, but in other forms the layers 66 can extend at an angle relative to the ligaments 64.
  • the direction that the layers are built is parallel with the direction in which the ligament extends.
  • the layers are built is transverse to the direction that the ligaments extend.
  • Fig. 3a depicts an alternating arrangement in which a layer 66 includes adjacent layers 66 that are either both longer or both shorter.
  • Fig. 3b depicts another embodiment in which the surface of the passage 62 is also alternating, but not every adjacent layer 66 is longer or shorter than its neighbor.
  • the surface of the passage 62 can be alternating in which individual layers 66 make up the texture of the surface.
  • the layers 66 can include corners 68 near their edges which can be used to assist in discouraging passage of a contaminant through the passage 62.
  • the edges can be the corners 68 as will be described in one or more embodiments below. It will be appreciated that although the illustrated embodiments show layers 66 of different heights, in some embodiments two or more layers either adjacent each other or within the same filter 54 can have the same height.
  • the edge of the layers 66 are depicted as having an end that meets the top and bottom of the layers at an angle, but not all embodiments need include such a shape.
  • top and bottom are used for ease of convenience in the description of the figures and are not limited to the “top” and “bottom” of any particular layer in any particular embodiment of the filter 54.
  • end refers to an outer extent of the layer and is not meant to imply any particular shape of the layer.
  • the end of the layer can be a periphery, or portion of a periphery, of a layer. In some forms the ends of the layers can be arranged such that the top and bottom of the layers converge to a point or rounded edge.
  • top and bottom of the layers can converge with the end using rounded corners.
  • Other shapes of the edge are also contemplated herein.
  • the end of any given layer can vary in position relative to the other ends of layers around the periphery of the filter 54. For example, though in one portion of the periphery an end of a layer may be positioned between two adjacent ends that extend further from the filter 54, in another portion of the periphery the end may extend further than either or both of its neighbors.
  • the layers can be formed according to a build file or other useful device capable of manufacturing the filter 54 that sets forth the extent of the edges of the layers 66.
  • the build file can include commands that set forth the edge location of each of the layers to create the alternating structure described above and as otherwise contemplated herein. The commands to set forth the shape and location of the edge can be based upon a desired filtering capability which dictates the form of the surface. Construction techniques other than those described above are also contemplated to set forth the alternating surface of the passages 62.
  • Fig. 4 one embodiment of the passage 62 and ligament 64 is shown in which a number of edges 70 of the surface of the passage 62 are illustrated.
  • the edges 70 appear to create an undulating variation in the surface of the passage 62.
  • the edges 70 can be representative of a single layer 66 or multiple layers depending on the needs of any given application and the construction of any given filter 54.
  • Fig. 5 depicts yet another embodiment of the surface of the passage 62.
  • Fig. 6 also depicts another embodiment of the surface of the passage 62.
  • the particle 72 is shown as having been captured by the filter 54.
  • the orientation, shape, and/or size of the passages 62 can assist in discouraging passage of a
  • the surface of the passage 62 can also have an orientation, shape, and/or size, among other characteristics, that assist in discouraging passage of contaminant through the filter.
  • the characteristics of the passage 62 can be used to discourage passage of a size of contaminant, while the characteristics of the surface of the passage 62 can be used to discourage passage of another size of contaminant.
  • the contaminant size discouraged by the passage can range upward from a minimal size, while the contaminant size discouraged by the surface of the passage 62 can range downward from a maximum size.
  • Other variations of the filtering capacity of the filter 54 are contemplated. For example, the minimum size and the maximum size can vary according to a particular location within the filter 54.
  • the minimum size and/or the maximum size may be the same across the entire filter 54 or portion(s) thereof. In some embodiments the minimum size can approach that of the maximum size through appropriate design of the surface and passage. Various characteristics such as size, shape, orientation, and location of the passage and its surface can be used to tune the filter to provide filtering of contaminant. Such tuning can be based upon a number of factors such as desired cleanliness of filtered liquid, type of filtered liquid, type of contaminant, among others. The tuning can be accomplished through the aid of computer modeling and empirical research, among others. Such tuning can be the result of a desired filtering range to be provided by the filter 54 according to any given application.
  • the filter 54 can be tuned to filter a broad range of contaminants using both the passages and the surface, while in another application the range of contaminants filtered by the passage and/or the surface are much narrower. Such differences can be the result of a requirements in a product produced from the filtering operation, such as a cast gas turbine engine blade, among potential others.
  • One aspect of the present application provides an apparatus comprising an investment casting filter used with a molten material and having a structure defined by a layered manufacturing process, the filter including a pore defined by a material of the filter, the pore sized to capture a first impurity from the molten material and the material having a texture to impede passage of a second impurity.
  • a feature of the present application provides wherein the investment casting filter includes a plurality of pores and wherein the first impurity is a larger size than the second impurity.
  • the first size impurity can be a size having a range extending upwards from a relatively small size
  • the second size impurity can have a size having a range extending downward from a relatively large size.
  • Yet another feature of the present application provides wherein the characteristics of the pore and texture are selected to provided a level of filtering.
  • Still another feature of the present application provides wherein the investment casting filter includes a plurality of graded pore sizes, and wherein the texture of the material is scalloped as a result of the layered build process.
  • the investment casting filter is a ceramic filter that includes alumina and is made via laser stereolithography.
  • a further feature of the present application provides wherein the pore is defined by a ligament which includes the surface, and which further includes a plurality of ligaments defining a plurality of pores.
  • Another aspect of the present application provides an apparatus comprising a molten metal filter used to remove contaminants from a molten metal, a pathway disposed in the molten metal filter and having a boundary, the pathway sized to block passage of a first contaminant, a surface of the boundary structured with a plurality of relatively high portions and plurality of relatively low portions that are selected to discourage passage of a second contaminant that is not blocked by the pathway.
  • the pathway includes a portion smaller in cross section than another portion of the pathway, and wherein the relatively high portions and relatively low portions are explicitly formed by a fabrication process.
  • the molten metal filter includes a plurality of pathways, wherein at least one of the pathways is a pore, and wherein the fabrication process is a free form fabrication process.
  • Yet another feature of the present application provides wherein the surface includes a plurality of corners defined by the relatively high portions and relatively low portions.
  • Still another feature of the present application provides wherein at least some of the plurality of relatively high portions and relatively low portions vary in height.
  • Still yet another feature of the present application provides wherein the plurality of relatively high portions and plurality of relatively low portions of the molten metal filter are formed from a layered manufacturing process and the geometry of which are selected based upon a desired level of filtering.
  • Yet another aspect of the present application provides an apparatus comprising a molten material filter structured to pass a filtered molten material to an investment casting mold, a pore disposed in the molten material filter sized to impede the conveyance of a first contaminant when a molten material is flowed through the filter, and means for targeted filtering of a second contaminant having a size smaller than the first contaminant.
  • a feature of the present application provides wherein the means for targeted filtering includes a pattern of peaks and valleys.
  • a further aspect of the present application provides a method comprising flowing a molten metal through a filter having a portion that defines a pathway, the portion including a free form fabricated texture arranged with an alternating contour selected to capture contaminant, discouraging the passage of a first impurity through interaction of the impurity and the pathway, and capturing a second impurity with the free form fabricated texture of the portion that defines the pathway.
  • the flowing includes inducing a pressure differential across the filter, and wherein the capturing includes attracting the second impurity to the roughness of the portion that defines the pathway.
  • Another feature of the present application further includes inducing turbulence as the molten material is flowed through the filter.
  • Yet another feature of the present application provides wherein the capturing includes holding the second impurity through one of surface tension or van der Wall forces.
  • Still another feature of the present application provides wherein the capturing includes conveying the molten metal across a plurality of valleys along the portion of the filter that defines the pathway.
  • Yet still another feature of the present application provides wherein the free form fabricated texture is selected based upon a filtering of the second impurity.
  • Yet a further aspect of the present application provides a method comprising constructing a molten material filter including building a pathway through the filter according to a determination to discourage flow of a first contaminant, creating corners in a surface of the filter according to a
  • a feature of the present application provides wherein the building includes forming a pore.
  • first contaminant includes a range extending upward from a minimum size and wherein the second contaminant includes a range extending downward from a maximum size.
  • first contaminant is of a first selected type of at least one of one of size, shape, and material.
  • Still another feature of the present application provides wherein the second contaminant is of a first selected type of at least one of one of size, shape, and material.
  • Yet still another feature of the present application provides wherein the constructing includes forming the molten material filter in layers.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Physics & Mathematics (AREA)
  • Acoustics & Sound (AREA)
  • Manufacturing & Machinery (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Filtering Materials (AREA)

Abstract

L'invention concerne un filtre dont la structure permet d'empêcher le passage d'un polluant dans un matériau en fusion. Le filtre peut être conçu pour bloquer un éventail de polluants. Par exemple, un passage peut être formé à l'intérieur du filtre et présenter une structure permettant d'empêcher le passage d'un polluant. La surface du passage peut être formée de manière à comprendre un certain nombre de parties alternatives qui sont utilisées pour permettre d'empêcher le passage d'un autre polluant susceptible de ne pas être bloqué par le passage.
PCT/US2012/072148 2011-12-29 2012-12-28 Filtre WO2013102127A2 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US201161581383P 2011-12-29 2011-12-29
US61/581,383 2011-12-29

Publications (2)

Publication Number Publication Date
WO2013102127A2 true WO2013102127A2 (fr) 2013-07-04
WO2013102127A3 WO2013102127A3 (fr) 2016-05-19

Family

ID=48698815

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US2012/072148 WO2013102127A2 (fr) 2011-12-29 2012-12-28 Filtre

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WO (1) WO2013102127A2 (fr)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US10493523B1 (en) 2016-02-04 2019-12-03 Williams International Co., L.L.C. Method of producing a cast component

Family Cites Families (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5104540A (en) * 1990-06-22 1992-04-14 Corning Incorporated Coated molten metal filters
CH685328A5 (de) * 1990-07-05 1995-06-15 Fischer Ag Georg Partikelabscheider zur Abtrennung von mitgeführten Partikeln aus einem flüssigen Metallstrom.
US5556592A (en) * 1994-08-15 1996-09-17 Hitchings; Jay Filter indexing apparatus for filtering molten metal
FR2780981B1 (fr) * 1998-07-09 2001-08-10 Membratec Sa Procede de filtration en ligne d'un metal liquide et dispositif pour la mise en oeuvre de ce procede
DE10102295A1 (de) * 2001-01-19 2002-08-08 Gkn Sinter Metals Gmbh Gradiert aufgebaute Filter und Verfahren zu ihrer Herstellung
KR100917271B1 (ko) * 2007-10-30 2009-09-21 대창공업 주식회사 금속 용탕 중의 불순물 제거를 위한 다층구조를 가지는필터
US8794298B2 (en) * 2009-12-30 2014-08-05 Rolls-Royce Corporation Systems and methods for filtering molten metal

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US10493523B1 (en) 2016-02-04 2019-12-03 Williams International Co., L.L.C. Method of producing a cast component

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