EP2551038A2 - Druckgusssystem und Verfahren - Google Patents

Druckgusssystem und Verfahren Download PDF

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Publication number
EP2551038A2
EP2551038A2 EP12178290A EP12178290A EP2551038A2 EP 2551038 A2 EP2551038 A2 EP 2551038A2 EP 12178290 A EP12178290 A EP 12178290A EP 12178290 A EP12178290 A EP 12178290A EP 2551038 A2 EP2551038 A2 EP 2551038A2
Authority
EP
European Patent Office
Prior art keywords
die
die casting
recited
casting system
charge
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.)
Granted
Application number
EP12178290A
Other languages
English (en)
French (fr)
Other versions
EP2551038B1 (de
EP2551038A3 (de
Inventor
Mario P. Bochiechio
John Joseph Marcin
Dilip M. Shah
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.)
RTX Corp
Original Assignee
United Technologies Corp
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 United Technologies Corp filed Critical United Technologies Corp
Publication of EP2551038A2 publication Critical patent/EP2551038A2/de
Publication of EP2551038A3 publication Critical patent/EP2551038A3/de
Application granted granted Critical
Publication of EP2551038B1 publication Critical patent/EP2551038B1/de
Not-in-force legal-status Critical Current
Anticipated expiration legal-status Critical

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D21/00—Casting non-ferrous metals or metallic compounds so far as their metallurgical properties are of importance for the casting procedure; Selection of compositions therefor
    • B22D21/06—Casting non-ferrous metals with a high melting point, e.g. metallic carbides
    • 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
    • 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
    • B22D17/08—Cold chamber machines, i.e. with unheated press chamber into which molten metal is ladled
    • B22D17/10—Cold chamber machines, i.e. with unheated press chamber into which molten metal is ladled with horizontal press motion
    • 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
    • B22D17/2209—Selection of die materials
    • 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
    • B22D21/00—Casting non-ferrous metals or metallic compounds so far as their metallurgical properties are of importance for the casting procedure; Selection of compositions therefor
    • B22D21/002—Castings of light metals
    • B22D21/005—Castings of light metals with high melting point, e.g. Be 1280 degrees C, Ti 1725 degrees C
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D21/00—Casting non-ferrous metals or metallic compounds so far as their metallurgical properties are of importance for the casting procedure; Selection of compositions therefor
    • B22D21/02—Casting exceedingly oxidisable non-ferrous metals, e.g. in inert atmosphere
    • B22D21/022—Casting heavy metals, with exceedingly high melting points, i.e. more than 1600 degrees C, e.g. W 3380 degrees C, Ta 3000 degrees C, Mo 2620 degrees C, Zr 1860 degrees C, Cr 1765 degrees C, V 1715 degrees C
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D21/00—Casting non-ferrous metals or metallic compounds so far as their metallurgical properties are of importance for the casting procedure; Selection of compositions therefor
    • B22D21/02—Casting exceedingly oxidisable non-ferrous metals, e.g. in inert atmosphere
    • B22D21/025—Casting heavy metals with high melting point, i.e. 1000 - 1600 degrees C, e.g. Co 1490 degrees C, Ni 1450 degrees C, Mn 1240 degrees C, Cu 1083 degrees C
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D25/00—Special casting characterised by the nature of the product
    • B22D25/02—Special casting characterised by the nature of the product by its peculiarity of shape; of works of art
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C27/00—Alloys based on rhenium or a refractory metal not mentioned in groups C22C14/00 or C22C16/00
    • C22C27/02—Alloys based on vanadium, niobium, or tantalum

Definitions

  • This disclosure relates generally to casting, and more particularly to a die casting system and method.
  • Casting is a known technique used to yield near net-shaped components.
  • investment casting is often used in the gas turbine engine industry to manufacture blades, vanes and other components having relatively complex geometries.
  • a component is investment cast by pouring molten metal into a ceramic shell having a cavity in the shape of the component to be cast.
  • the shape of the component is derived from a wax or SLA pattern that defines the shape of the component.
  • the investment casting process is capital intensive, requires a significant amount of manual labor, and can be time intensive.
  • Die casting offers another casting technique. Die casting involves injecting molten metal directly into a reusable die to yield a near net-shaped component.
  • the tooling of the die casting system, including the die, the shot tube and the shot tube plunger, are subjected to relatively high thermal loads and stresses during the die casting process.
  • a die casting system disclosed herein includes a die having a plurality of die elements that define a die cavity. A charge of material is received in the die cavity. The charge of material comprises a refractory metal intermetallic composite based material system.
  • a die casting system in another exemplary embodiment, includes a die having a plurality of die elements that define a die cavity. A charge of material is received in the die cavity.
  • the charge of material can include a composite material such as niobium silicide, molybdenum di-silicide, Nb5Si3+NbO+SiO2, NbSi2+Nb5Si3+SiO2, TaSi2+Ta5Si3+SiO2, W5Si3+W+SiO2, and WSi2+W5Si3+SiO2.
  • An exemplary method of die casting a component includes injecting a charge of material into a die having a plurality of die elements that define a die cavity configured to receive the charge of material.
  • the charge of material comprises a refractory metal intermetallic composite based material system.
  • Figure 1 illustrates an example die casting system 50 including a reusable die 52 having a plurality of die elements 54, 56 that function to cast a component 55 (See Figure 4 ). Although two die elements 54, 56 are depicted in Figure 1 , it should be understand that the die 52 could include a greater or fewer number of die elements, as well as other parts and configurations.
  • the die 52 is assembled by positioning the die elements 54, 56 together and holding the die elements 54, 56 at a desired positioning via a mechanism 58.
  • the mechanism 58 could include a clamping mechanism of appropriate hydraulic, pneumatic, electromechanical and/or other configurations.
  • the mechanism 58 also separates the die elements 54, 56 subsequent to casting.
  • the die elements 54, 56 define internal surfaces 62 that cooperate to define a die cavity 60.
  • a shot tube 64 is in fluid communication with the die cavity 60 via one or more ports 66 located in the die element 54, the die element 56 or both.
  • a shot tube plunger 68 is received within the shot tube 64 and is moveable between a retracted and injected position (in the direction of arrow A) within the shot tube 64 by a mechanism 80.
  • a shot rod 31 extends between the mechanism 80 and the shot tube plunger 68.
  • the mechanism 80 could include a hydraulic assembly or other suitable system including, but not limited to, pneumatic, electromechanical, hydraulic or any combination of the systems.
  • the shot tube 64 is positioned to receive a charge of material M from a melting unit 82, such as a crucible, for example.
  • the melting unit 82 can utilize any known technique for melting an ingot of metallic material to prepare the charge of material M for delivery to the shot tube 64, including but not limited to, vacuum induction melting, electron beam melting, induction skull melting and resistance melting.
  • the charge of material M is melted into molten metal in the melting unit 82 at a location that is separate from the shot tube 64 and the die cavity 60.
  • the melting unit 82 is positioned in close proximity to the shot tube 64 to reduce the required transfer distance between the charge of material M and the shot tube 64.
  • the charge of material M is transferred from the melting unit 82 to the shot tube 64 in a known manner, such as pouring the charge of material M into a pour hole 63 in the shot tube 64, for example.
  • a sufficient amount of molten metal is poured into shot tube 64 to fill the die cavity 60.
  • the shot tube plunger 68 is actuated to inject the charge of material M under pressure from the shot tube 64 into the die cavity 60 to cast a component 55.
  • the die casting system 50 could be configured to cast multiple components in a single shot.
  • the die casting system 50 can be positioned within a vacuum chamber 90 that includes a vacuum source 92.
  • a vacuum is applied in the vacuum chamber 90 via the vacuum source 92 to render a vacuum die casting process.
  • the vacuum chamber 90 provides a non-reactive environment for the die casting system 50 and reduces reaction, contamination or other conditions that could detrimentally affect the quality of the die cast component, such as excess porosity in the cast component resulting from exposure to air.
  • the vacuum chamber 90 is maintained at a pressure 5x10-3 Torr (0.66 Pascal) and 1x10-6 Torr (0.000133 Pascal), although other pressures are contemplated.
  • the actual pressure of the vacuum chamber 90 will vary based on the type of component 55 cast, among other conditions and factors.
  • each of the melting unit 82, the shot tube 64 and the die 52 are positioned within the vacuum chamber 90 during the die casting process such that the melting, injecting and solidifying of the charge of material M are each performed under vacuum.
  • the vacuum chamber 90 is vacuum filled with an inert gas, such as argon, for example.
  • the example die casting system 50 depicted by Figure 1 is illustrative only and could include a greater or fewer number of sections, parts and/or components. This disclosure extends to all forms of die casting, including but not limited to, horizontal, vertical, inclined or other die casting configurations.
  • Figures 2A and 2B illustrate portions of the die casting system 50 during casting ( Figure 3A ) and after the die elements 54, 56 separate ( Figure 3B ).
  • the die elements 54, 56 are disassembled relative to the component 55 by opening the die 52 via the mechanism 58.
  • ejector pins 84 are used to remove the components 55 from the die cavity 60.
  • a die release agent may be applied to the die elements 54, 56 of the die 52 prior to injection to achieve a simpler release of the component 55 from the die 52 post-solidification.
  • the cast component 55 may include an equiaxed structure upon solidification, or could include other structures.
  • An equiaxed structure includes a randomly oriented grain structure having multiple grains.
  • a composite material is used to die cast the component 55.
  • “composite” is defined as a refractory metal intermetallic composite (or, RMIC).
  • RMIC's contain a member or members of the family of refractory elements. These elements include tungsten, rhenium, tantalum, molybdenum, and niobium. These elements are combined with an intermetallic element such as silicon.
  • Example composites include, but are not limited to, niobium silicide (NbSi) and molybdenum di-silicide (MoSi2).
  • Nb5Si3+NbO+SiO2 NbSi2+Nb5Si3+SiO2
  • TaSi2+Ta5Si3+SiO2 W5Si3+W+SiO2
  • WSi2+W5Si3+SiO2 WSi2+W5Si3+SiO2.
  • Additional intermetallic compounds include, but are not limited to, Nickel Aluminides of general composition NiAI and Ni3AI (but can contain alloying elements such as: Co, Cr, Pt, Si, Re, Rh, Ta, Y, Er, Gd, Zr and/or Hf); Titanium Aluminide of the general compositions TiA1, TiA12, TiA13 (but can contain alloying elements such as Mn, V, Nb, Ta, Fe, Co, Cr, Ni, B, W, Mo, Cu, Zr, and/ or Si); and Platinum Aluminide of general composition PtAl (but can contain alloying elements such as, but not limited to, Ni, Co, Cr, Pt, Si, Rh, Ta, Y, Er, Gd, and/or Hf).
  • Nickel Aluminides of general composition NiAI and Ni3AI but can contain alloying elements such as: Co, Cr, Pt, Si, Re, Rh, Ta, Y, Er, Gd, Zr and/or Hf
  • Die casting components using a charge of material such as the RMIC's noted above provides an improved casting process without the need to develop or reengineer the ceramic systems that are used in a traditional investment casting process.
  • Figure 3 illustrates additional features that can be incorporated into the die casting system 50.
  • the die elements 54, 56 can be selectively heated with a heating system 100, such as a die heater, if necessary.
  • die inserts of the die elements 54, 56 can include layers of a highly conductive material to aid in the temperature control of the die inserts.
  • Example highly conductive materials could include a thermal conductivity of at least 310 W/m*K and a melting temperature of at least 960°C (1760°F). Materials such as copper, gold and silver are examples of such highly conductive materials that can be used in the construct of portions of the die elements 54, 56.
  • the highly conductive material rapidly conducts heat away from the die elements 54, 56 during the casting process to extend tooling life.
  • the die elements 54, 56 can also be selectively cooled with a cooling system 104 as necessary due to the extreme heat experienced during the casting process.
  • a cooling system 104 for example, a die casting hot oil technology can be used, or other radiative or conductive cooling techniques such as liquid metal cooling, in order to cool the die elements 54, 56 and a die base 102 during the casting process.
  • Figure 4 illustrates an example component 55 that can be cast in a die casting process.
  • the component 55 is an airfoil for a gas turbine engine.
  • this disclosure is not limited to the casting of airfoils.
  • the example die casting system 50 of this disclosure may be utilized to cast aeronautical components including blades, vanes, combustor panels, blade outer air seals (boas), or any other components that could be subjected to extreme environment, including non-aeronautical components.
  • the die cast component 55 can include an internal geometry 38 defined within the component 55 (i.e., the component 55 is at least partially hollow).
  • the internal geometry 38 defines a microcircuit cooling scheme for a turbine vane.
  • the internal geometry 38 could also define other advanced cooling schemes to facilitate additional heat transfer.
  • weight reduction tongues i.e., voids
  • the component 55 can be cast using the example die casting system 50 described above.
  • Die casting of the component 55 with the materials noted above allows for the production of a fine, uniform grain size that will improve the properties and materials.
  • solidification rates will be increased significantly by transitioning refractory metal alloys and/or composite to die casting.
  • the rapid melting of the charge of material from ingot stock reduces the potential for reactivity with the die casting system 50 tooling due to the ability of the die casting tooling to disperse heat away from the final casting geometry. In other words, the bulk of the die tooling is able to absorb the heat and effectively move it to other areas of the die.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
  • Manufacture Of Alloys Or Alloy Compounds (AREA)
EP12178290.8A 2011-07-29 2012-07-27 Druckgusssystem und Verfahren Not-in-force EP2551038B1 (de)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US13/193,730 US20130025816A1 (en) 2011-07-29 2011-07-29 Die casting system and method

Publications (3)

Publication Number Publication Date
EP2551038A2 true EP2551038A2 (de) 2013-01-30
EP2551038A3 EP2551038A3 (de) 2017-03-15
EP2551038B1 EP2551038B1 (de) 2020-12-16

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EP12178290.8A Not-in-force EP2551038B1 (de) 2011-07-29 2012-07-27 Druckgusssystem und Verfahren

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US (3) US20130025816A1 (de)
EP (1) EP2551038B1 (de)

Cited By (1)

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CN118268534A (zh) * 2024-06-04 2024-07-02 北华航天工业学院 一种铝制品快速压铸成型模具

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US9511418B2 (en) * 2012-10-01 2016-12-06 United Technologies Corporation Method of casting parts using heat reservoir, gating used by such method, and casting made thereby
US20170087627A1 (en) * 2013-02-19 2017-03-30 United Technologies Corporation Die configuration for high temperature diecasting
CN106604791A (zh) * 2014-09-08 2017-04-26 西门子公司 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
KR102232517B1 (ko) * 2014-09-15 2021-03-26 삼성전자주식회사 이미지 촬영 방법 및 이미지 촬영 장치
CN110756768B (zh) * 2019-10-24 2023-12-29 贵州裕高电子有限责任公司 一种可实现飞行器尾翼一次成型的压铸模芯及其使用方法

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Publication number Priority date Publication date Assignee Title
CN118268534A (zh) * 2024-06-04 2024-07-02 北华航天工业学院 一种铝制品快速压铸成型模具

Also Published As

Publication number Publication date
EP2551038B1 (de) 2020-12-16
US20210346947A1 (en) 2021-11-11
US20130025816A1 (en) 2013-01-31
US20160167122A1 (en) 2016-06-16
EP2551038A3 (de) 2017-03-15

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