EP1027180B1 - Feinguss - Google Patents

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Publication number
EP1027180B1
EP1027180B1 EP98954632A EP98954632A EP1027180B1 EP 1027180 B1 EP1027180 B1 EP 1027180B1 EP 98954632 A EP98954632 A EP 98954632A EP 98954632 A EP98954632 A EP 98954632A EP 1027180 B1 EP1027180 B1 EP 1027180B1
Authority
EP
European Patent Office
Prior art keywords
shell
casting
cast
vacuum
ceramic
Prior art date
Legal status (The legal status 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 status listed.)
Expired - Lifetime
Application number
EP98954632A
Other languages
English (en)
French (fr)
Other versions
EP1027180A1 (de
Inventor
Michael Cornelius Ashton
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
CASTINGS TECHNOLOGY INTERNATIONAL
Original Assignee
Castings Development Centre
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Filing date
Publication date
Application filed by Castings Development Centre filed Critical Castings Development Centre
Publication of EP1027180A1 publication Critical patent/EP1027180A1/de
Application granted granted Critical
Publication of EP1027180B1 publication Critical patent/EP1027180B1/de
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22DCASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D18/00Pressure casting; Vacuum casting
    • B22D18/06Vacuum casting, i.e. making use of vacuum to fill the mould
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22CFOUNDRY MOULDING
    • B22C7/00Patterns; Manufacture thereof so far as not provided for in other classes
    • B22C7/02Lost patterns
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22CFOUNDRY MOULDING
    • B22C9/00Moulds or cores; Moulding processes
    • B22C9/02Sand moulds or like moulds for shaped castings
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22CFOUNDRY MOULDING
    • B22C9/00Moulds or cores; Moulding processes
    • B22C9/02Sand moulds or like moulds for shaped castings
    • B22C9/04Use of lost patterns
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22CFOUNDRY MOULDING
    • B22C9/00Moulds or cores; Moulding processes
    • B22C9/08Features with respect to supply of molten metal, e.g. ingates, circular gates, skim gates
    • B22C9/082Sprues, pouring cups

Definitions

  • This invention relates to the casting of articles of molten metal and is particularly concerned with casting by the so-called investment or lost wax process.
  • a very accurate model of the required product is produced in wax.
  • a ceramic shell is then formed around the wax by applying successive coats of ceramic slurry and stucco.
  • the wax is dipped into a tank of slurry; on removal, excess slurry adhering to the wax model is drained off and dry granular ceramic stucco is applied to the surface either by raining it over the model, or by immersing the model in a fluidised bed containing the stucco.
  • the first coating must be dried before the next coating can be applied.
  • the resultant shell is then cooled to room temperature, repaired and cleaned of any internal debris, after which it is heated for several hours in a pre-heat furnace before being taken to a casting furnace or casting station to be filled with metal while at high temperature.
  • Pre-heating is necessary to avoid thermal shock and to ensure that the mould fills completely, especially in thin sections. In many foundries, the same furnace is used for all firing and pre-heating operations which reduces capital investment but leads to logistical and productivity constraints.
  • Investment casting offers a manufacturing process capable of producing components of high definition, good dimensional accuracy and excellent surface finish. Its drawbacks, however are that it is limited in the size of components which can be cast and it is expensive to operate. One problem is caused by the fact that wax expands on heating and this can cause the surrounding ceramic shell to crack. It is one object of this invention to address these drawbacks by providing a casting process capable of delivering the benefits of investment casting but which is applicable over a greater size range and is cheaper to operate.
  • EP-A- 474 078 discloses an investment casting method using vacuum for filling the mould formed by a ceramic shell, which, apart from step 8) of claim 8, namely applying a vacuum to the granular filler surrounding the shell, comprises all the steps mentioned in claim 8.
  • At least the initial slurry used for coating the wax pattern is water based.
  • the thickness of the thin-walled shell mould produced by the coating is about 2.5 mm.
  • the temperature of firing and steam treatment in an autoclave to remove the wax is 135-176°C; a further firing treatment in order to improve gas permeability is not necessary, cf. such a step missing in the claims of the EP-A, but is mentioned taking place at 985°C in the description of the EP-A.
  • the shell mould is placed in a box within loose particulate refractory media which are densified by vibration. A vacuum is not applied to the particulate refractory media but to the interior of the shell before and during the metal pouring step.
  • US-A-3 933 190 discloses investment casting of turbine blades from Ni- or Co-based superalloys.
  • the invention provides a method of casting an article of molten metal, the method comprising casting the liquid metal into a supported thin ceramic shell having a smooth surface and which has not been pre-heated before ingress of the liquid metal and including the preliminary step of supporting the shell in a bed of compacted granular material and applying a vacuum to the compact granular material while the liquid metal is being cast into the shell whereby to draw all the metal into the shell.
  • a mould which is cast hot must be strong enough to withstand being handled at high temperature and also to avoid breakout during pouring. This is achieved by building up a substantial thickness of shell consisting of as many as 15 dip coats.
  • the mould is cold at the point when the molten metal is poured. into it and it is supported in a bed of loose sand compacted to a high bulk density. In this process it is normal to apply only 5 to 7 coats depending on the size and geometry of the casting being produced leading to very significant savings in moulding materials, mould manufacturing lead time, work in progress and waste disposal costs.
  • VOC volatile organic compound
  • moulds are cast cold, it is possible to cast several components together from a single large charge of metal. (Pre-heated, investment cast moulds are usually cast individually, each mould requiring a small, single billet of metal to be melted and poured, which is time consuming and costly.)
  • the ceramic shell is supported in a bed of granular material, for example, sand, while the molten metal is being cast into the shell. It is also preferred that the bed of granular material be at or near ambient temperature.
  • the sand is compacted, preferably by vibration, before pouring and it is further compacted by applying a vacuum while the metal is being poured.
  • the vibration is preferably of high frequency and low amplitude, typically 40 - 50 Hz and 0.045 mm RMS (root mean square) to optimise compaction of the backing material and to provide acceptable support for the mould.
  • the thickness of the ceramic shell is typically around 3 mm, i.e. relatively thin compared to most investment casting shells and is made by applying a relatively small number of slurry and stucco coat; each coat being dried before the next is applied. For most castings only five coats need to be applied to provide the necessary shell thickness.
  • the ceramic slurries used to form the coatings which make up the shell mould are preferably water-based. Suitable materials for use in these slurries include, but are not restricted to, zircon, silica, alumina and the alumino-silicate group of materials.
  • the invention provides a method of casting an article of molten metal, the method comprising the steps of:
  • the casting method is applicable to a wide range of alloys including iron, steel, aluminium, cobalt/ chrome and nickel based superalloys.
  • a further adaptation of this process is its application to vacuum cast alloys, e.g. nickel-based or cobalt-based superalloys.
  • the alloy to be cast is melted under vacuum in a vacuum melting furnace.
  • a bed of granular material containing the mould is positioned inside the casting chamber of the furnace; the granular material in the bed having been vibrated in advance to compact it.
  • An inert gas e.g. argon
  • a pump is activated which draws the inert gas through the mould and the bed of granular material and then re-admits it into the casting chamber.
  • the invention includes components cast by the method.
  • the second and subsequent coatings were of back-up material, comprising a slurry of fused silica filler and water-based colloidal silica binder and a stucco of MolochiteTM, an alumino-silicate material produced from china clay.
  • five coatings were applied, including the primary coat. Drying times between coats ranged from 36 minutes between coats 1 and 2 to 54 minutes between coats 4 and 5. After coat 5 was applied, the mould was left for 20 hours in the drying room before removing the wax in a steam autoclave and firing at 1050°C in a gas fired kiln to remove all traces of wax. Drying conditions used throughout mould build and final dry were 23°C dry bulb temperature and 55% relative humidity.
  • the cold shell S was placed in a mould box 3 measuring 1m x 1m x 1m.
  • Sub-angular silica sand 4 was then poured into the bed around the outside of the mould.
  • the box was vibrated at a frequency of 40 - 50 Hz and displacement of 0.045 mm RMS (root mean square) for a period of 90 seconds. This compacted the sand ensuring a high bulk density and intimate contact of the sand with all areas of the mould.
  • a vacuum of approximately 500 mm measured at the pump mercury gauge was drawn in the sand bed and steel was then poured into the cold shell via a plenum chamber 5 in the base of the box.
  • the invention is not limited to the embodiments shown.
  • the top of the box may be covered by a sheet and/or protective gas may be supplied during casting.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
  • Pyridine Compounds (AREA)
  • Soil Working Implements (AREA)
  • Dental Prosthetics (AREA)
  • Mold Materials And Core Materials (AREA)
  • Sorption Type Refrigeration Machines (AREA)
  • Control Of Steam Boilers And Waste-Gas Boilers (AREA)

Claims (11)

  1. Verfahren zum Gießen eines Artikels aus geschmolzenem Metall, wobei das Verfahren ein Gießen des flüssigen Metalls in einen gestützten dünnen Keramikmantel umfasst, der eine glatte Oberfläche aufweist und vor dem Eindringen des flüssigen Metalls nicht vorgeheizt worden ist, und den vorhergehenden Schritt des Stützens des Mantels in einem Bett aus verdichtetem granularen Material und Anlegen eines Vakuums an das dichte granulare Material umfasst, während das flüssige Metall in den Mantel gegossen wird, wodurch das gesamte Metall in den Mantel gezogen wird.
  2. Verfahren nach Anspruch 1, wobei eine einzige Charge geschmolzenen Metalls verwendet wird, um eine Zahl von Komponenten zu gießen, wobei ein Keramikmantel in einer Gießoperation gebildet wird.
  3. Verfahren nach Anspruch 2, das dazu ausgelegt ist, eine Zahl von Kraftfahrzeug- oder allgemeinen industriellen Gußerzeugnissen zu gießen.
  4. Verfahren nach einem der vorhergehenden Ansprüche, wobei die Wanddicke des Keramikmantels weniger als ungefähr 3 mm beträgt.
  5. Verfahren nach Anspruch 4, umfassend den vorhergehenden Schritt des Formens des Keramikmantels durch aufeinanderfolgendes Aufbringen von Schichten eines Beschichtungsmaterials auf ein Wachsmuster, um die definierte Wanddicke zu bilden, und durch Entfernen des Wachsmusters, um einen handhabbaren Keramikmantel zu bilden.
  6. Verfahren nach Anspruch 5, wobei das Beschichtungsmaterial keramischer Schlamm auf Wasserbasis und ein trockener granularer Keramikstuck ist.
  7. Verfahren nach einem der vorhergehenden Ansprüche, wobei das flüssige Metall unter einer Inertgas-Schutzatmosphäre gegossen wird.
  8. Verfahren nach Anspruch 1, wobei das Verfahren die Schritte umfasst:
    1) Bilden eines Musters der zu gießenden Komponente(n) und des zugeordneten Angußsystems aus Wachs;
    2) Eintauchen des Wachsmusters in einen Tank mit keramischem Schlamm, umfassend einen feuerfesten Füller sowie ein Bindemittel auf Wasserbasis, um eine Beschichtung auf dem Muster zu bilden;
    3) Ablaufenlassen des überschüssigen Schlamms und Aufbringen von feuerfesten Körnern auf die Beschichtung, um eine Stuckschicht darauf zu bilden, und anschließendes Trocknenlassen der Beschichtung;
    4) Wiederholen der Schritte (3) und (4), um eine Beschichtung mit einer Dicke von ungefähr 3 mm zu bilden;
    5) Entfernen des Wachses und Abkühlenlassen des resultierenden Mantels auf Raumtemperatur;
    6) Anordnen des Mantels in einen Formkasten und Umgeben desselben mit granularem Füller;
    7) Schütteln des Kastens, um den Füller auf eine hohe Fülldichte zu verdichten;
    8) Anlegen eines Vakuums an den granularen Füller;
    9) Gießen geschmolzenen Metalls in den Mantel, während das Vakuum beibehalten wird;
    10) Entfernen des Vakuums, Abkühlenlassen des Gußerzeugnisses und anschließendes Trennen desselben vom Füller; und
    11) Entfernen des Mantels, um ein Gußerzeugnis zu liefern, das eine im Wesentlichen glatte Außenoberfläche aufweist.
  9. Verfahren nach Anspruch 8, bei dem der Schlamm ein Schlamm auf Wasserbasis ist.
  10. Verfahren nach Anspruch 8 oder 9, wobei verschiedene Artikel in dem einen Formkasten unter Verwendung der einzigen Charge geschmolzenen Metalls gegossen werden.
  11. Verfahren nach einem der Ansprüche 8 bis 10, angewandt auf das Gießen von Artikeln aus einer Superlegierung, wobei im folgenden Schritt (7) der Formkasten in die Gießkammer eines Vakuumschmelzofens gesetzt wird, ein Inertgas in die Kammer eingelassen und eine Pumpe eingeschaltet wird, um Inertgas durch den Formkasten zu saugen, und die Legierung unter Vakuum geschmolzen und in den Kasten gegossen wird, um hierdurch einen Artikel aus der Superlegierung und mit einer glatten Ausführung zu bilden.
EP98954632A 1997-11-19 1998-11-18 Feinguss Expired - Lifetime EP1027180B1 (de)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
GB9724568 1997-11-19
GBGB9724568.2A GB9724568D0 (en) 1997-11-19 1997-11-19 Investment casting
PCT/GB1998/003472 WO1999025511A1 (en) 1997-11-19 1998-11-18 Investment casting

Publications (2)

Publication Number Publication Date
EP1027180A1 EP1027180A1 (de) 2000-08-16
EP1027180B1 true EP1027180B1 (de) 2005-01-05

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EP98954632A Expired - Lifetime EP1027180B1 (de) 1997-11-19 1998-11-18 Feinguss

Country Status (5)

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EP (1) EP1027180B1 (de)
AT (1) ATE286443T1 (de)
DE (1) DE69828523T2 (de)
GB (1) GB9724568D0 (de)
WO (1) WO1999025511A1 (de)

Families Citing this family (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US7258158B2 (en) 2004-07-28 2007-08-21 Howmet Corporation Increasing stability of silica-bearing material
IL234824A (en) 2014-09-23 2016-02-29 Ofer Hen Foundry system, molding method, method of manufacture and method of casting using it
CN104439074A (zh) * 2014-11-27 2015-03-25 宁波通达精密铸造有限公司 一种熔模精密铸造方法
KR101755832B1 (ko) * 2015-08-31 2017-07-10 현대자동차주식회사 자동차 배기계용 정밀주조부품 제조방법

Family Cites Families (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3933190A (en) * 1974-12-16 1976-01-20 United Technologies Corporation Method for fabricating shell molds for the production of superalloy castings
US4026344A (en) * 1976-06-23 1977-05-31 General Electric Company Method for making investment casting molds for casting of superalloys
US4222429A (en) * 1979-06-05 1980-09-16 Foundry Management, Inc. Foundry process including heat treating of produced castings in formation sand
CA2049228C (en) * 1990-09-06 1996-10-15 George D. Chandley Countergravity casting using particulate supported thin walled investment shell mold

Also Published As

Publication number Publication date
WO1999025511A1 (en) 1999-05-27
ATE286443T1 (de) 2005-01-15
DE69828523D1 (de) 2005-02-10
GB9724568D0 (en) 1998-01-21
DE69828523T2 (de) 2005-10-13
EP1027180A1 (de) 2000-08-16

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