EP2067546A1 - Systèmes pour mouler de manière centrifuge des métaux en titane hautement réactif - Google Patents

Systèmes pour mouler de manière centrifuge des métaux en titane hautement réactif Download PDF

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Publication number
EP2067546A1
EP2067546A1 EP08169706A EP08169706A EP2067546A1 EP 2067546 A1 EP2067546 A1 EP 2067546A1 EP 08169706 A EP08169706 A EP 08169706A EP 08169706 A EP08169706 A EP 08169706A EP 2067546 A1 EP2067546 A1 EP 2067546A1
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EP
European Patent Office
Prior art keywords
crucible
induction
metal
molten metal
titanium
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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.)
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EP08169706A
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German (de)
English (en)
Inventor
Thomas Joseph Kelly
Michael James Weimer
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General Electric Co
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General Electric Co
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D13/00—Centrifugal casting; Casting by using centrifugal force

Definitions

  • Embodiments described herein generally relate to systems for centrifugally casting highly reactive metals. More particularly, embodiments herein generally describe systems for centrifugally casting highly reactive titanium alloys, and in particular, titanium aluminide alloys.
  • Titanium alloys Ti alloys
  • TiAl alloys titanium aluminide based alloys
  • TiAl alloys possess a promising combination of low-temperature mechanical properties, such as room temperature ductility and toughness, as well as high intermediate temperature strength and creep resistance.
  • TiAl alloys have the potential to replace nickel-based superalloys, which are currently used to make numerous turbine engine components.
  • Vacuum Arc Re-melting is one technique commonly used to melt Ti alloys.
  • VAR generally involves striking an arc between a titanium alloy electrode and pieces of the same alloy (electrode ends, for example) placed in a water-cooled copper crucible. A molten pool is established and the electrode progressively melts. When sufficient molten metal is available, the electrode can be withdrawn and the crucible tilted to pour the metal into a mold for casting components.
  • Titanium electrodes used in the VAR process can be expensive because of the high cost of titanium billets/forgings, and the high cost of labor involved in creating an electrode from certified scrap or revert material. Also, the requirement for a pre-alloyed electrode can make it difficult and expensive to produce non-standard alloys. Furthermore, the need to use a water-cooled crucible can limit the degree of superheat achievable in the metal, which in turn can affect fluidity, leading to difficulty in filling thin-wall castings. Moreover, the highest temperature exists where the arc strikes the metal, and high temperature gradients exist in the molten metal. This can also affect the filling of molds and sets up poor temperature gradients in the solidifying casting.
  • VIM Vacuum Induction Melting
  • Vacuum induction melting generally involves heating a metal in a crucible made from a non-conductive refractory alloy oxide until the charge of metal within the crucible is melted down to liquid form.
  • pieces of solid titanium alloy are placed in a cooled metal hearth, usually made of copper, and melted in an inert atmosphere using a very intense heat source, such as an arc or plasma.
  • a molten pool will form initially on the interior and top surface of the charge of titanium while the titanium adjacent to the confining wall of the copper hearth remains solid.
  • This "skull" of solid titanium that develops contains the liquid titanium metal free of contamination. See U.S. Patent No. 4,654,858, issued to Rowe for a general discussion of cold wall induction melting.
  • copper crucibles are most often employed in cold wall induction melting of highly reactive alloys for a number of reasons.
  • melting and casting from ceramic crucibles can introduce significant thermal stress on the crucible, which can result in the crucible cracking.
  • Such cracking can reduce crucible life and cause inclusions in the component being cast.
  • the highly reactive TiAl alloys can break down the ceramic crucible and contaminate the titanium alloy with both oxygen and the refractory alloy from the oxide.
  • the titanium aluminide can dissolve large quantities of carbon from the crucible into the titanium alloy, thereby resulting in contamination. Such contamination can result in a loss of mechanical properties of the titanium alloy.
  • Copper is less likely to exhibit the previously described problems associated with ceramic and graphite crucibles, which is why copper crucibles are typically employed when using cold wall induction melting to melt highly reactive metal alloys.
  • cold crucible melting in copper crucibles can offer metallurgical advantages for the processing of the highly reactive alloys described previously, it can also have a number of technical and economic limitations including low superheat, yield losses due to skull formation and high power requirements.
  • the cold wall induction crucible suffers heat loss when the power to the crucible is terminated and the metal is allowed to slump against the water-cooled copper sides of the mold.
  • nozzles can provide many benefits over other common practices, the use of nozzles is not entirely without the potential for complications. For example, cold hearth melting and bottom pouring of reactive metals like titanium can result in undesirable melt freeze-off in the nozzle. In addition, many crucible/nozzle systems can struggle to provide the requisite control of liquid flow rate, minimize erosion of the nozzle, and minimize melt contamination.
  • levitation melting Another development that has been employed to address the previously described issues with vacuum induction melting is levitation melting, which generally involves using energy from induction coils to electromagnetically suspend the metal being melted. See U.S. Patent 5,275,229, issued to Fishman et al . for a general discussion of levitation melting.
  • the magnetic induction field can both heat the metal and hold the molten metal suspended in space within the crucible, once the power source for the system is turned off, the metal can slip back into the water-cooled crucible and chill again before it can be poured. This can result in incomplete filling of the mold.
  • Embodiments herein generally relate to systems for centrifugally casting a highly reactive titanium metal comprising a cold wall induction crucible for containing a titanium metal charge, the induction crucible having a plurality of induction coils and a removable bottom plate, a power source to heat the titanium metal charge in the induction crucible to obtain a molten metal, a preheated secondary crucible for catching the molten metal as it falls from the induction crucible after the removable bottom plate has been withdrawn and the power source turned off, and a centrifugal casting machine for holding and accelerating the secondary crucible to centrifugally force the molten metal into a casting mold and produce a cast component.
  • Embodiments herein also generally relate to systems for centrifugally casting a highly reactive titanium metal comprising a cold wall induction crucible for containing a titanium metal charge, the induction crucible having a plurality of induction coils and a removable bottom plate, a power source to heat the titanium metal charge in the induction crucible to obtain a molten metal, a preheated secondary crucible for catching the molten metal as it falls from the induction crucible after the removable bottom plate has been withdrawn and the power source turned off, a funnel for transferring the molten metal from the induction crucible to the secondary crucible, and a centrifugal casting machine for holding and accelerating the secondary crucible to centrifugally force the molten metal into a casting mold and produce a cast component.
  • Embodiments also generally relate to systems for centrifugally casting a highly reactive titanium metal comprising a cold wall induction crucible for containing a titanium aluminide charge, the induction crucible having a plurality of induction coils and a slidably removable bottom plate, a power source to heat the titanium aluminide charge in the induction crucible to obtain a molten titanium aluminide, a preheated secondary crucible for catching the molten titanium aluminide as it falls from the induction crucible after the removable bottom plate has been withdrawn and the power source turned off, a niobium funnel for transferring the molten titanium aluminide from the induction crucible to the secondary crucible, and a centrifugal casting machine for holding the secondary crucible stationary for from about 0.5 to about 2 seconds after the molten titanium aluminide falls into the secondary crucible and, thereafter, accelerating the secondary crucible to from about 100 rpm to about
  • Embodiments described herein generally relate to systems for centrifugally casting highly reactive metals, and in particular titanium alloys and titanium aluminide alloys, into net shape components, though the description that follows should not be limited to such.
  • a cold wall induction crucible 10 having a body 12 can be provided, as shown in FIG. 1 .
  • Body 12 can be made from any metal having good thermal and electrical conductivity, such as, for example copper.
  • Body 12 may be water-cooled to prevent the copper from melting during the heating of the crucible. More particularly, copper generally melts at about 1900°F (about 1038°C) and TiAl melts at about 2600°F (about 1427°C), and the copper in the crucible can form a low melting eutectic with the titanium. Water-cooling the crucible can prevent this from occurring. Water-cooling inlet 24 and outlet 26 may be used to circulate the cooling water through a plurality of channels 28 positioned about body 12.
  • body 12 may have any shape desired and acceptable for use in induction melting, in one embodiment, body 12 may be generally shaped as a hollow cylinder. Body 12 may have a plurality of induction coils 14 positioned thereabout, which can be heated using a power source 21. Coils 14 can serve as a heat source to melt a metal charge placed within the crucible and maintain its molten state, as described herein below.
  • Crucible 10 may also have a removable bottom plate 16 as shown in FIG.1 .
  • bottom plate 16 may comprise any metal having good thermal and electrical conductivity, and in one embodiment, may comprise copper.
  • Bottom plate 16 may also be water-cooled and have a plurality of induction coils 14 positioned thereunder, again, to help melt the metal charge placed with crucible 10 and maintain its molten state.
  • an electric insulator plate 19 may circumscribe bottom plate 16 to help maintain heat in the bottom of crucible 10.
  • bottom plate 16 may be removed from body 12 in a variety of manners, including, but not limited to, sliding (as shown in FIGS. 2 and 3 ), rotating, dropping and the like.
  • metal charge 18 comprising a highly reactive alloy may be placed inside body 12 of crucible 10 as shown in FIG. 1 .
  • metal charge 18 may comprise a titanium alloy, and more specifically a titanium aluminide alloy, and may take any acceptable form, which may include, but should not be limited to, lumps, ingots, granules, plates, powders, and mixtures thereof.
  • the amount of metal charge 18 placed into crucible 10 can vary depending on intended use, however, in one embodiment, from about 1 pound (about 454 grams) to about 3.5 pounds (about 1588 grams), and in another embodiment from about 1.25 pounds (about 567 grams) to about 3.3 pounds (about 1497 grams) of metal charge 18 can be used to make net shaped low-pressure turbine blades as described herein below.
  • a cover 20 which in one embodiment, may be made from the same material as crucible 10, may be positioned on top of body 12 and held in place with a cover ring 22, to ensure crucible 10 is sealed.
  • Power source 21 may be turned on and metal charge 18 can melt when the appropriate temperature is attained, which in one embodiment may be from about 2700°F to about 2835°F (about 1480°C to about 1557 °C).
  • the electromagnetic field generated by the induction coils causes the metal charge to heat itself internally due to resistance heating caused by current flow within the metal charge.
  • the resulting molten metal 30 may become suspended within body 12 of crucible 10 such that molten metal 30 does not come into contact with the inside of body 12 as long as the power is being supplied to crucible 10. This suspension of molten metal 30 can prevent the formation of a skull.
  • a secondary crucible 32 Concurrent with melting the metal charge in induction crucible 10, a secondary crucible 32, or other like holding device, may be preheated using any acceptable means, such as, but not limited to, microwave or radiant energy.
  • Secondary crucible may be made from graphite or ceramic, and may optionally have a metal liner, such as for example, niobium.
  • Secondary crucible 32 can aid in the transfer of the molten metal to a casting mold without losing any of the superheat in the molten metal generated during induction melting in the induction crucible 10.
  • secondary crucible 32 can be preheated to at least about 1832°F (about 1000 °C), and in one embodiment from about 1832°F to about 2200°F (1000°C to about 1200°C), when secondary crucible 32 comprises niobium, and to at least about 1980°F (about 1082 °C), and in one embodiment from about 1980°F to about 2400°F (1082°C to about 1316°C), when secondary crucible comprises ceramic. Preheating can help prevent thermal shock and cracking of secondary crucible 32, which would allow for reuse thereof.
  • Preheated secondary crucible 32 may then be placed in the rotating arm 34 of a centrifugal casting machine 36 and positioned below induction crucible 10, as shown generally in FIG. 3 . Any conventional centrifugal casting machine is acceptable for use herein, such as for example, the Linn High-Therm Titancast 700 (Germany) or the SEIT Supercast (Italy).
  • Removable bottom plate 16 may then be withdrawn from body 12 of crucible 10, as previously described.
  • bottom plate 16 may be slidably removed from crucible 10 using any acceptable mechanism, such as, but not limited to, tracks or guides.
  • the electromagnetic field generated by induction coils 14 can maintain molten metal 30 in a suspended state within body 12 of crucible 10 as shown in FIG. 2 , until further processing.
  • molten metal 30 is allowed to fall from induction crucible 10 through a niobium funnel 33 and into preheated secondary crucible 32, which can remain stationary within casting machine 36 just long enough for molten metal 30 to complete its transfer into secondary crucible 32, which in one embodiment may be from about 0.5 to about 2 seconds.
  • secondary crucible 32 can be rapidly (about 1 to about 2 seconds) accelerated to full speed, which may be from about 100 rpm to about 600 rpm.
  • Casting machine 36 can centrifugally force molten metal 30 out of secondary crucible 32 and into casting mold 38 through port 40, which may comprise at least one of a slit, hole, tube, or combination thereof.
  • This quick transfer from secondary crucible 32 to casting mold 38 results in a contact time between the two of less than about 5 seconds.
  • This brief contact time not only significantly reduces heat loss, but also helps ensure that there is no undesirable reaction between the molten metal and the graphite or ceramic used to construct secondary crucible 32.
  • Casting mold 38 may comprise any ceramic investment casting system that provides an inert face coat and thermal insulating backing materials.
  • casting mold 38 may comprise a face coat including an oxide.
  • oxide refers to a composition selected from the group consisting of scandium oxide, yttrium oxide, hafnium oxide, a lanthanide series oxide, and combinations thereof.
  • the lanthanide series oxide (also known as "rare earth” compositions) may comprise an oxide selected from the group consisting of lanthanum oxide, cerium oxide, praseodymium oxide, neodymium oxide, promethium oxide, samarium oxide, europium oxide, gadolinium oxide, terbium oxide, dysprosium oxide holmium oxide, erbium oxide, ytterbium oxide, lutetium oxide, and combinations thereof.
  • Casting mold 38 may comprise a backing including a refractory material selected from the group consisting of aluminum oxide, zirconium silicate, silicon dioxide, and combinations thereof, in a colloidal silica suspension.
  • centrifugal casting machine 36 can be turned off.
  • the resulting component which in one embodiment may be a low pressure turbine blade 42, as shown in FIG. 4 , can be removed from casting mold 38 using conventional practices. Because of the use of centrifugal casting, blade 42 needs little post-cast processing.
  • the centrifugal forces generated by casting machine 36 provides for the optimized filling of casting mold 38 by improving the filling of thin sections of the mold, thereby providing a net shape component.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Crucibles And Fluidized-Bed Furnaces (AREA)
  • Manufacture And Refinement Of Metals (AREA)
  • Turbine Rotor Nozzle Sealing (AREA)
EP08169706A 2007-11-27 2008-11-21 Systèmes pour mouler de manière centrifuge des métaux en titane hautement réactif Ceased EP2067546A1 (fr)

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US11/945,388 US20090133850A1 (en) 2007-11-27 2007-11-27 Systems for centrifugally casting highly reactive titanium metals

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US (1) US20090133850A1 (fr)
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JP (1) JP2009125810A (fr)
KR (1) KR20090054921A (fr)
TW (1) TW200940208A (fr)

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2011048423A1 (fr) * 2009-10-21 2011-04-28 Societe Europeene Des Technologies Du Titane Et Des Alliages Speciaux Sa. Moulage de produits longs
WO2015092220A1 (fr) * 2013-12-20 2015-06-25 Snecma Procédé de fabrication d'une pièce de turbomachine, ébauche intermédiaire et moule obtenus
WO2015092239A1 (fr) * 2013-12-20 2015-06-25 Snecma Procédé de fabrication de pièces de turbomachine, ébauche à pièces superposées et moule obtenus
WO2015092218A1 (fr) * 2013-12-20 2015-06-25 Snecma Procédé de fabrication de pièces de turbomachine, ébauche et moule obtenus

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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
US10597756B2 (en) 2012-03-24 2020-03-24 General Electric Company Titanium aluminide intermetallic compositions
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
CN103008634B (zh) * 2012-11-16 2015-04-08 云南钛业股份有限公司 一种利用海绵钛保护容器进行熔炼的方法
US8992824B2 (en) 2012-12-04 2015-03-31 General Electric Company Crucible and extrinsic facecoat compositions
EP2931458B1 (fr) * 2012-12-14 2019-02-06 United Technologies Corporation Coulage à multiples injections
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
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
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
US10391547B2 (en) 2014-06-04 2019-08-27 General Electric Company Casting mold of grading with silicon carbide
CN110317967A (zh) * 2019-06-19 2019-10-11 西部超导材料科技股份有限公司 一种改善大规格tc4钛合金铸锭凝固组织的方法
CN113275541B (zh) * 2021-05-25 2022-06-14 哈尔滨工业大学 大尺寸复杂非晶合金构件逆重力充填成形装置
KR102704965B1 (ko) * 2021-06-15 2024-09-09 (주)동아특수금속 유도 스컬 용해법을 적용한 Zircaloy 스크랩 재 주조공정

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Cited By (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2011048423A1 (fr) * 2009-10-21 2011-04-28 Societe Europeene Des Technologies Du Titane Et Des Alliages Speciaux Sa. Moulage de produits longs
CN102869465A (zh) * 2009-10-21 2013-01-09 钛合金特殊技术欧洲股份公司 铸造长材产品
WO2015092220A1 (fr) * 2013-12-20 2015-06-25 Snecma Procédé de fabrication d'une pièce de turbomachine, ébauche intermédiaire et moule obtenus
WO2015092239A1 (fr) * 2013-12-20 2015-06-25 Snecma Procédé de fabrication de pièces de turbomachine, ébauche à pièces superposées et moule obtenus
WO2015092218A1 (fr) * 2013-12-20 2015-06-25 Snecma Procédé de fabrication de pièces de turbomachine, ébauche et moule obtenus
FR3015327A1 (fr) * 2013-12-20 2015-06-26 Snecma Procede de fabrication de pieces de turbomachine, ebauche et moule obtenus
FR3015326A1 (fr) * 2013-12-20 2015-06-26 Snecma Procede de fabrication de pieces de turbomachine, ebauche a pieces superposees et moule obtenus
FR3015325A1 (fr) * 2013-12-20 2015-06-26 Snecma Procede de fabrication d'une piece de turbomachine, ebauche intermediaire et moule obtenus
US9796058B2 (en) 2013-12-20 2017-10-24 Snecma Method for producing turbine engine parts, and resulting mould and blank compromising stacked parts
US9844843B2 (en) 2013-12-20 2017-12-19 Snecma Method for producing turbine engine parts, and resulting blank and mould
US9969035B2 (en) 2013-12-20 2018-05-15 Snecma Method for producing a turbine engine part, and resulting mould and intermediate blank

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JP2009125810A (ja) 2009-06-11
KR20090054921A (ko) 2009-06-01
TW200940208A (en) 2009-10-01
US20090133850A1 (en) 2009-05-28

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