WO2016039715A1 - Système de coulée sous pression hybride pour la formation d'un élément utilisable dans une turbine à gaz - Google Patents

Système de coulée sous pression hybride pour la formation d'un élément utilisable dans une turbine à gaz Download PDF

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Publication number
WO2016039715A1
WO2016039715A1 PCT/US2014/054463 US2014054463W WO2016039715A1 WO 2016039715 A1 WO2016039715 A1 WO 2016039715A1 US 2014054463 W US2014054463 W US 2014054463W WO 2016039715 A1 WO2016039715 A1 WO 2016039715A1
Authority
WO
WIPO (PCT)
Prior art keywords
die
cooling
hybrid
die cast
cast system
Prior art date
Application number
PCT/US2014/054463
Other languages
English (en)
Inventor
Alexander Ralph Beeck
Allister William James
Gary B. Merrill
Original Assignee
Siemens Aktiengesellschaft
Siemens Energy, Inc.
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 Siemens Aktiengesellschaft, Siemens Energy, Inc. filed Critical Siemens Aktiengesellschaft
Priority to CN201480081803.2A priority Critical patent/CN106604791A/zh
Priority to JP2017513256A priority patent/JP2017534459A/ja
Priority to PCT/US2014/054463 priority patent/WO2016039715A1/fr
Priority to EP14780658.2A priority patent/EP3191241A1/fr
Priority to US15/508,938 priority patent/US20170274447A1/en
Publication of WO2016039715A1 publication Critical patent/WO2016039715A1/fr

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
    • B22D17/20—Accessories: Details
    • B22D17/22—Dies; Die plates; Die supports; Cooling equipment for dies; Accessories for loosening and ejecting castings from dies
    • B22D17/229—Dies; Die plates; Die supports; Cooling equipment for dies; Accessories for loosening and ejecting castings from dies with exchangeable die part
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
    • B22D17/20—Accessories: Details
    • B22D17/22—Dies; Die plates; Die supports; Cooling equipment for dies; Accessories for loosening and ejecting castings from dies
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
    • B22D17/20—Accessories: Details
    • B22D17/22—Dies; Die plates; Die supports; Cooling equipment for dies; Accessories for loosening and ejecting castings from dies
    • B22D17/2218—Cooling or heating equipment for dies
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
    • B22D17/20—Accessories: Details
    • B22D17/32—Controlling equipment

Definitions

  • This invention is directed generally to die cast systems, and more particularly to manufacturing methods for turbine airfoils usable in turbine engines.
  • Die casting is traditionally limited to the casting of non-ferrous alloys because it is challenging to use the die cast process for high temperature materials such as nickel based superalloys.
  • molten metal may be forced into a mold under high pressure. This process is typically used for large volume production as there is a high initial capital investment cost associated with manufacturing the dies.
  • Most die castings are made from non-ferrous alloys such as zinc, aluminum, and magnesium. Die casting is capable of producing dimensionally consistent parts.
  • Investment casting using a lost wax process is typically employed for manufacturing turbine components made from high temperature materials, such as nickel based superalloys. Investment casting is often used to form components, such as blades, vanes and ring segments. Investment casting is a versatile process that enables the casting of complex shapes that are not possible with traditional die casting. Internal cavities may be incorporated into a turbine component through use of the cores with the investment casting process.
  • a hybrid die cast system having an inner liner insert that enables the configuration of a component produced by the system to be easily changed by changing the inner liner insert without having to rework a die housing is disclosed. Because the inner liner insert only need be removed and replaced to change the configuration of an outer surface of a component produced by the system, the cost savings is significant in contrast with conventional systems in which the die would have to be reworked.
  • the system may also include a die cooling system for controlling the casting process by controlling the rate of solidification and the rate of cooling of the casting. Local heating and cooling may be used to control the microstructure, enhance mold fill and reduce casting defects such as porosity.
  • the hybrid die cast system may include a die housing having one or more inner chambers and one or more inner liners positioned within the inner chamber of the die housing.
  • the inner liner may have an inner surface defining boundaries useful to form an outer surface of a component.
  • the inner surface of the inner liner may be configured to form the component of a gas turbine engine.
  • the inner surface of the inner liner may be configured to form an airfoil usable in a gas turbine engine.
  • the hybrid die cast system may include one or more casting cores positioned in the inner chamber of the die housing to create an inner cooling system within the airfoil.
  • the hybrid die cast system may also include one or more intermediate liners positioned between the inner liner and an inner surface of the inner chamber in the die housing. The intermediate liner may be formed from one or more compliant materials allowing for differential expansion to occur.
  • the hybrid die cast system may also include one or more die cooling systems formed from one or more serpentine cooling channels positioned within the inner liner.
  • the die cooling system may include one or more cooling fluid supply manifolds in fluid communication with inlets of a plurality of cooling channels and one or more cooling fluid collection manifolds in fluid communication with outlets of the plurality of cooling channels.
  • the die cooling system may also include one or more valves for controlling flow of cooling fluids through the die cooling system.
  • the hybrid die cast system may also include one or more die heating systems formed from one or more heating channels positioned within the die housing.
  • a method of forming a component of a gas turbine engine may include positioning one or more casting cores in an inner chamber of a die housing, wherein the die housing has at least one inner chamber and at least one inner liner positioned within the inner chamber of the die housing and wherein the inner liner may have an inner surface defining boundaries useful to form an outer surface of a component.
  • the method may also include injecting molten metal into the inner chamber of the die housing defined by the inner surface of the inner liner.
  • the method may also include controlling a rate of solidification and a rate of cooling of the casting via at least one die cooling system formed from one or more serpentine cooling channels positioned within the inner liner and including one or more cooling fluid supply manifolds in fluid communication with inlets of a plurality of cooling channels, one or more cooling fluid collection manifolds in fluid
  • An advantage of the hybrid die cast system is that because the inner liner insert only need be removed and replaced to change the configuration of an outer surface of a component produced by the system, a significant cost savings is captured in contrast with conventional systems in which the die would have to be reworked.
  • Another advantage of the hybrid die cast system is that the die cooling system and die heating system may be used to control the rate of solidification and the rate of cooling of the casting component and local heating and cooling may be used to control the microstructure, enhance mold fill and reduce casting defects such as porosity.
  • the die cooling system and die heating system may be used to retain molten alloy in certain locations of the casting component, especially in sections where mold fill may otherwise be difficult.
  • Another advantage of the hybrid die cast system is that use of the hybrid die cast system will reduce time and effort required to build a shell in a conventional casting process.
  • Figure 1 is a cross-sectional view of the hybrid die cast system.
  • Figure 2 is a cross-sectional view of the die cooling system and heating system of the hybrid die cast system.
  • Figure 3 is cross-sectional view of another embodiment of the die cooling system and heating system of the hybrid die cast system.
  • Figure 4 is a perspective view of an airfoil usable in a gas turbine engine.
  • Figure 5 is a cross-sectional view of the airfoil shown in Figure 5 taken at section line 5-5 in Figure 4.
  • a hybrid die cast system 10 having an inner liner insert 12 that enables the configuration of a component 14 produced by the system 10 to be easily changed by changing the inner liner insert 12 without having to rework a die housing 16 is disclosed. Because the inner liner insert 12 only need be removed and replaced to change the configuration of an outer surface 18 of a component 14 produced by the system 10, the cost savings is significant in contrast with conventional systems in which the die would have to be reworked.
  • the system 10 may also include a die cooling system 20 for controlling the casting process by controlling the rate of solidification and the rate of cooling of the casting. Local heating and cooling may be used to control the microstructure, enhance mold fill and reduce casting defects such as porosity.
  • the hybrid die cast system 10 may include a die housing 16 having at least one inner chamber 22 and one or more inner liners 12 positioned within the inner chamber 22 in the die housing 16.
  • the inner liner 12 may have an inner surface 24 defining boundaries useful to form an outer surface 18 of a component 14.
  • One or more inner liners 12 may be positioned within the inner chamber 22 of the die housing 16 such that the inner liner 12 may have an inner surface 24 defining boundaries useful to form an outer surface 18 of a component 14.
  • the inner surface 24 of the inner liner 12 may be configured to form the component 14 of a gas turbine engine, as shown in Figures 4 and 5.
  • the inner surface 24 of the inner liner 12 may be configured to form an airfoil 28 usable in a gas turbine engine.
  • the airfoil 28 may be formed from a generally elongated, hollow airfoil 60 having a leading edge 62 on an opposite side from a trailing edge 64 and separated by a concave pressure side 66 and a convex suction side 68.
  • One or more casting cores 61 may be positioned in the inner chamber 22 of the die housing 16 to form one or more channels of an internal cooling system in the airfoil 28.
  • the die housing 16 may be formed from a first die subhousing 56 and a second die subhousing 58.
  • the inner liner 12 may be formed, at least in part, from one or more ceramic materials.
  • the ceramic liner 12 may form a shell that may be used to produce features in the casting that would not be possible with
  • the ceramic liner 12 may be formed in any appropriate manner, such as, but not limited to, flexible silicon technology, or an additive manufacturing process, such as, but not limited to, three dimensional printing or selective laser melting.
  • the configuration of the inner surface 24 of the ceramic liner 12 may be changed to change the configuration of the outer surface 18 of a component 14 formed within the hybrid die cast system 10 without having to rework the die housing 16. As such, a significant cost savings is realized.
  • the ceramic liner 12 may also provide a barrier between the molten metal used to form the component 14 within the inner chamber 22 of the liner 12, thereby preventing the molten metal from contacting the die housing 16 during the casting process.
  • the hybrid die cast system 10 may include one or more intermediate liners 30 positioned between the inner liner 12 and an inner surface 32 of the inner chamber 22 in the die housing 16.
  • the intermediate liner 30 may be formed from one or more compliant materials allowing for differential expansion to occur.
  • the intermediate liner 30 may accommodate any dimensional mismatch between the die housing 16 and the inner liner 12.
  • the intermediate layer 30 may be formed from an unfired ceramic, i.e. green state.
  • the hybrid die cast system 10 may also include one or more die cooling systems 20 formed from one or more cooling channels 38 or one or more heating systems 36, or both, for controlling the casting process.
  • the heating and cooling systems 20, 36 may be used to control the rate of solidification and the rate of cooling of the casting component 14. Local heating and cooling may be used to control the microstructure, enhance mold fill and reduce casting defects such as porosity.
  • the heating and cooling systems 20, 36 may be used to retain molten alloy in certain locations of the casting component 14, especially in sections where mold fill may otherwise be difficult.
  • the cooling system 20 may be configured to provide cooling to the hybrid die cast system 10 via embedded cooling channels 38.
  • the cooling fluid used within the cooling system 20 may be, but is not limited to being, a gas, e.g.
  • the heating and cooling systems 20, 36 may be used to form temperature gradients within the hybrid die cast system 10 to promote directional solidification.
  • the die cooling system 20 may be formed from one or more serpentine cooling channels 38 positioned within the inner liner 12.
  • the one cooling channels 28 may be positioned at an interface 40 between the liner 12 and one or more intermediate liners 30, positioned between the liner 12 and the inner surface 32 defining the inner chamber 22 in the die housing 16, positioned within the inner liner 12, positioned within the die housing 16, positioned within the intermediate liner 30, or any combination thereof.
  • the die cooling system 20 may include one or more cooling fluid supply manifolds 42 in fluid communication with inlets 44 of a plurality of cooling channels 38 and one or more cooling fluid collection manifolds 46 in fluid communication with outlets 48 of the plurality of cooling channels 38.
  • One or more cooling circuits may be formed within the die cooling system 20.
  • multiple cooling circuits may be formed within the die cooling system 20.
  • the die cooling system 20 may also include one or more valves 50 for controlling flow of cooling fluids through the die cooling system 20, and in particular, through the plurality of cooling circuits.
  • the die cooling system 20 may include a plurality of valves configured to control the cooling system 20 to switch the cooling fluid on and off in a manner that allows the cooling fluid to move according to the solidification location of the liquid metal.
  • the die cooling system 20 may also include one or more chill plates 54. In at least one embodiment, the chill plate 54 may be positioned within the die housing 16.
  • the hybrid die cast system 10 may also include one or more die heating systems 36 formed from one or more heating channels 52 positioned within the die housing 16.
  • the heating system 36 may include electrical resistance heating elements 54, which, in at least one embodiment, may be strategically placed induction coils 54 or other appropriate heat sources.
  • One or more aspects of the heating system 36 such as, but not limited to the heating channels 52, may be positioned at an interface 40 between the liner 12 and one or more intermediate liners 30, positioned between the liner 12 and the inner surface 32 defining the inner chamber 22 in the die housing 16, positioned within the inner liner 12, positioned within the die housing 16, positioned within the intermediate liner 30, or any combination thereof.
  • the hybrid die cast system 10 may include the die cooling system 20 and the heating system 36 to move a thermal field, and more specifically, to achieve crystal growth through use of a plurality of circuits with the die cooling system 20 in conjunction with the heating system 36.
  • the hybrid die cast system 10 may be used in a number of manners.
  • the hybrid die cast system 10 may be used in a method of forming a component 14 of a gas turbine engine including positioning one or more casting cores 61 in at least one inner chamber 22 of a die housing 16, whereby the die housing 16 may have one or more inner chambers 22 and one or more inner liners 12 positioned within the inner chamber 22 of the die housing 16.
  • the inner liner 12 may have an inner surface 24 defining boundaries useful to form an outer surface 26 of a component 14.
  • the method may also include injecting molten metal into the inner chamber 22 of the die housing 16 defined by the inner surface 24 of the inner liner 12.
  • the method may also include controlling a rate of solidification and a rate of cooling of the casting via one or more die cooling systems 20 formed from at least one serpentine cooling channel 38 positioned within the inner liner 12 and one or more cooling fluid supply manifolds 42 in fluid communication with inlets 44 of a plurality of cooling channels 38, at least one cooling fluid collection manifold 46 in fluid communication with outlets 48 of the plurality of cooling channels 38 and at least one valve 50 for controlling flow of cooling fluids through the die cooling system 20.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Turbine Rotor Nozzle Sealing (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)

Abstract

L'invention concerne un système de coulée sous pression hybride (10) comprenant une pièce rapportée d'habillage intérieur (12) qui permet de changer facilement la configuration d'un élément (18) produit par le système (10) par changement de la pièce rapportée d'habillage intérieur (12) sans avoir à retravailler l'enveloppe (16) de la matrice. Du fait qu'on n'a seulement besoin de retirer et de remplacer la pièce rapportée d'habillage intérieur (12) pour changer la configuration d'une surface externe (18) d'un élément (18) produit par le système (10), les économies sont importantes par contraste avec les systèmes classiques dans lesquels la matrice devrait être retravaillée. Le système (10) peut également comprendre un système de refroidissement (20) pour le réglage du processus de coulée par réglage de la vitesse de solidification et de la vitesse de refroidissement de la pièce coulée. Le chauffage et le refroidissement locaux peuvent être utilisés pour régler la microstructure, améliorer le remplissage du moule et réduire les défauts de la pièce coulée tels que la porosité.
PCT/US2014/054463 2014-09-08 2014-09-08 Système de coulée sous pression hybride pour la formation d'un élément utilisable dans une turbine à gaz WO2016039715A1 (fr)

Priority Applications (5)

Application Number Priority Date Filing Date Title
CN201480081803.2A CN106604791A (zh) 2014-09-08 2014-09-08 用于形成可用于燃气涡轮发动机中的部件的混合压铸系统
JP2017513256A JP2017534459A (ja) 2014-09-08 2014-09-08 ガスタービンエンジンに使用可能な構成要素を成形するためのハイブリッドダイカストシステム
PCT/US2014/054463 WO2016039715A1 (fr) 2014-09-08 2014-09-08 Système de coulée sous pression hybride pour la formation d'un élément utilisable dans une turbine à gaz
EP14780658.2A EP3191241A1 (fr) 2014-09-08 2014-09-08 Système de coulée sous pression hybride pour la formation d'un élément utilisable dans une turbine à gaz
US15/508,938 US20170274447A1 (en) 2014-09-08 2014-09-08 Hybrid die cast system for forming a component usable in a gas turbine engine

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/US2014/054463 WO2016039715A1 (fr) 2014-09-08 2014-09-08 Système de coulée sous pression hybride pour la formation d'un élément utilisable dans une turbine à gaz

Publications (1)

Publication Number Publication Date
WO2016039715A1 true WO2016039715A1 (fr) 2016-03-17

Family

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Application Number Title Priority Date Filing Date
PCT/US2014/054463 WO2016039715A1 (fr) 2014-09-08 2014-09-08 Système de coulée sous pression hybride pour la formation d'un élément utilisable dans une turbine à gaz

Country Status (5)

Country Link
US (1) US20170274447A1 (fr)
EP (1) EP3191241A1 (fr)
JP (1) JP2017534459A (fr)
CN (1) CN106604791A (fr)
WO (1) WO2016039715A1 (fr)

Families Citing this family (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN108213381A (zh) * 2018-01-22 2018-06-29 广德盛源电器有限公司 一种铝合金件压铸机
CN109759560B (zh) * 2019-04-01 2019-12-31 江苏祥和电子科技有限公司 一种具有快速冷却降温功能的铝合金压铸模具
CN113695549A (zh) * 2021-08-24 2021-11-26 张英华 一种装有合金内衬或内胆的压力铸造制品的制作方法

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EP2450126A2 (fr) * 2010-11-05 2012-05-09 United Technologies Corporation Système de moulage et procédé utilisant des matériaux à température de fusion élevée
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DE102007054723A1 (de) * 2007-11-14 2009-05-20 Cl Schutzrechtsverwaltungs Gmbh Formteil
DE102009008675A1 (de) * 2009-02-12 2010-08-19 Audi Ag Gussform zum Druckgießen eines Bauteils sowie Verfahren zur Herstellung einer derartigen Gussform
WO2012020204A1 (fr) * 2010-08-12 2012-02-16 C.T.I.F. -Centre Technique Des Industries De La Fonderie Dispositif pour le moulage d'une piece mince
EP2450126A2 (fr) * 2010-11-05 2012-05-09 United Technologies Corporation Système de moulage et procédé utilisant des matériaux à température de fusion élevée
WO2014130245A1 (fr) * 2013-02-19 2014-08-28 United Technologies Corporation Conception de matrice pour coulée sous pression haute température

Also Published As

Publication number Publication date
US20170274447A1 (en) 2017-09-28
JP2017534459A (ja) 2017-11-24
CN106604791A (zh) 2017-04-26
EP3191241A1 (fr) 2017-07-19

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