EP3907018A1 - Wärmemanagement beim wachsausschmelzguss - Google Patents

Wärmemanagement beim wachsausschmelzguss Download PDF

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Publication number
EP3907018A1
EP3907018A1 EP21172009.9A EP21172009A EP3907018A1 EP 3907018 A1 EP3907018 A1 EP 3907018A1 EP 21172009 A EP21172009 A EP 21172009A EP 3907018 A1 EP3907018 A1 EP 3907018A1
Authority
EP
European Patent Office
Prior art keywords
ceramic mold
wax
temperature control
assembly
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.)
Granted
Application number
EP21172009.9A
Other languages
English (en)
French (fr)
Other versions
EP3907018B1 (de
Inventor
John Joseph Marcin
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.)
Hamilton Sundstrand Corp
Original Assignee
Hamilton Sundstrand Corp
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Filing date
Publication date
Application filed by Hamilton Sundstrand Corp filed Critical Hamilton Sundstrand Corp
Publication of EP3907018A1 publication Critical patent/EP3907018A1/de
Application granted granted Critical
Publication of EP3907018B1 publication Critical patent/EP3907018B1/de
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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C19/00—Components or accessories for moulding machines
    • B22C19/04—Controlling devices specially designed for moulding machines
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C21/00—Flasks; Accessories therefor
    • B22C21/12—Accessories
    • B22C21/14—Accessories for reinforcing or securing moulding materials or cores, e.g. gaggers, chaplets, pins, bars
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C7/00—Patterns; Manufacture thereof so far as not provided for in other classes
    • B22C7/02—Lost patterns
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/02—Sand moulds or like moulds for shaped castings
    • B22C9/04—Use of lost patterns
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/02—Sand moulds or like moulds for shaped castings
    • B22C9/04—Use of lost patterns
    • B22C9/043—Removing the consumable pattern
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/08—Features with respect to supply of molten metal, e.g. ingates, circular gates, skim gates
    • B22C9/082—Sprues, pouring cups
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/10—Cores; Manufacture or installation of cores
    • B22C9/103—Multipart cores
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D15/00—Casting using a mould or core of which a part significant to the process is of high thermal conductivity, e.g. chill casting; Moulds or accessories specially adapted therefor

Definitions

  • the embodiments herein relate to casting of materials and more specifically to thermal management in lost wax casting.
  • Investment casting may include a wax part pattern of an article to be cast, which may be produced from a die mold.
  • the component wax pattern may be connected with injected wax shapes on a wax assembly, which will typically possesses a pour-cup, down-sprue, wax in-gates, and then the component pattern itself.
  • the wax tree, with the part patterns, is then coated with a ceramic slurry to form a ceramic shell over its surface.
  • the wax assembly may then be withdrawn from the slurry and dried.
  • the steps of coating and drying are repeated until a ceramic shell mold around the wax tree is of a sufficient thickness, which may depend on the weight of the cast assembly.
  • the wax tree, with the ceramic shell is then placed in a furnace pressurized steam de-waxer vessel removes the wax from the inside of the ceramic mold.
  • the ceramic mold is then placed into a furnace to heat and sinter the ceramic particles to strengthen the mold to enable the receipt of a certain volume of molten metal.
  • the hardening may be in a separate thermal processing step.
  • the ceramic mold is then ready for the casting of the part. Molten metal is poured into the pour-cup and passed through the sprue and ingates into the component cavity once defined by the wax assembly. After the metal has solidified, the ceramic shell is removed mechanically to reveal the metal components on the assembly. The cast components are then removed from the assembly, mechanically finished and inspected. The ceramic shell is mechanically removed, e.g., by blunt force (or other mechanical action), after the metal is hardened.
  • the wax tree is placed within a flask, which is then filled with the ceramic slurry.
  • the flask, with the hardened ceramic may be placed in a furnace and heated to remove the wax, and to harden the ceramic coating.
  • the hardening may be in a separate heat-treating step.
  • the ceramic mold is then ready for casting.
  • molten metal is also poured into the pour-cup and then passes into the down-sprue and runner system to feed the component pattern(s).
  • the ceramic is also mechanically removed after the metal is solidified. Parts cast from these processes should be relatively defect free to meet manufacturing needs.
  • a lost-wax method of casting a product including: attaching temperature control elements to a wax assembly; encasing the wax assembly and the temperature control elements in a ceramic mold; removing the wax assembly from the ceramic mold; filling the ceramic mold with molten material to form a cast part within the ceramic mold; and separating the ceramic mold and the cast part from each other.
  • the temperature control elements are thermal sink elements and the method includes attaching the thermal sink elements to a part pattern section of the wax assembly.
  • the method includes attaching the insulating elements to a sprue pattern section and gate-land pattern sections of the wax assembly.
  • the temperature control elements are steel blocks of different sizes
  • the method includes: attaching the steel blocks to the part pattern section to draw heat from the molten material.
  • the method further includes positioning the thermal sink elements closer to first portions of the part pattern section of the wax assembly than second portions of the part pattern section of the wax assembly, wherein the first portions are thicker than the second portions.
  • the method further includes positioning the thermal sink elements about one or more of side, front and back surfaces of the wax assembly.
  • the method further includes attaching the temperature control elements directly to the wax assembly.
  • the method further includes forming the ceramic mold about the wax assembly to a first thickness to define a first layer of the ceramic mold; and attaching the temperature control elements to the first layer of the ceramic mold.
  • the method further includes forming the ceramic mold about the wax assembly to a second thickness that is greater than the first thickness to encase the temperature control elements within the ceramic mold.
  • the method further includes forming the ceramic mold about the wax assembly to the second thickness by repeatedly: drenching the wax assembly in a ceramic slurry; and drying the ceramic slurry.
  • the method further includes forming the ceramic mold about the wax assembly to the second thickness by: positioning the wax assembly in a flask; and filling the flask with a ceramic slurry.
  • the method further includes separating the ceramic mold and the cast part from each other by mechanical action.
  • the method further includes thermally removing wax from and firing the ceramic mold to sinter the ceramic and prepare the ceramic mold for casting.
  • a mold assembly including: a wax assembly including: a part pattern section; temperature control elements connected to the wax assembly, wherein: a ceramic mold encasing the wax assembly and the temperature control elements.
  • the temperature control elements include thermal sink elements spaced apart from each other and connected to the part pattern section.
  • mold assembly includes: a gate pattern section connected around an outer surface the part pattern section and defining a sprue pattern section and gate-land pattern sections; and the temperature control elements include insulating elements connected to the sprue pattern section and the gate-land pattern sections.
  • the temperature control elements are disposed between layers of ceramic in the ceramic mold.
  • a ceramic mold defining: a part pattern chamber; a gate section formed around the part pattern chamber and defining a sprue and gate-lands; and temperature control elements encased in the ceramic mold.
  • the temperature control elements include: thermal sink elements spaced apart from each other within the part pattern chamber.
  • the temperature control elements include: insulating elements disposed within the sprue and the gate-lands.
  • molten metal may undesirably solidify within the sprue, runners or assembly gating as well as within the component to which the assembly gating is attached before reaching the part pattern chamber. This may, result in casting defects which would cause the need for rework and repair, or would scrap the parts.
  • the molten metal may cool unevenly within the part pattern chamber due to a variation of geometries within the part pattern chamber. For example, a relatively large mass of molten metal at thicker portions of a part pattern may result in an excess of heat in the same location compared with a thinner portion of the part pattern. Thus, thicker portions may cool more slowly than thinner portions of the part pattern within the part pattern chamber. The cooling dynamics may result in undesirable residual stress and strain in the final cast part.
  • the temperature control elements 100 take the form of thermal sink elements (or chillers) 100A1-100A5 (generally referenced as 100A).
  • the thermal sink elements 100A are respectively applied to first portions 210A1, 210A2 (generally referenced as 210A) of a part pattern section 120 of a wax assembly 140 (or wax investment).
  • the thermal sink elements 100A are applied to a side surface 125A, also referred to as an outer surface, of the part pattern section 120.
  • the part pattern section 120 is three dimensional and thus has front and back surfaces 125B, 125C, identified schematically, and the thermal sink elements 100A may be applied there as well.
  • thermal sink elements 100A4, 100A5 are schematically shown for the front and back surfaces 125B, 125C, respectively.
  • the first portions 210A are relatively thick portions of the part pattern section 120 compared with, e.g., second portions 220B1, 220B2 (generally referenced as 220B) which may be near the respective first portions 210A.
  • the thermal sink elements 100A are configured to provide for thermal control of the casting process by drawing out excess heat from molten material 180 utilized during the casting process. Faster solidification in areas of greater mass will result in more sound cast metal with less micro-porosity and macro-porosity defects. This is especially true if the area of larger mass is contained within regions of small mass where proper metal fill and solidification are not possible.
  • the temperature control elements 100 take the form of insulating elements (or thermal barriers) 100B1-100B6 (generally referenced as 100B).
  • the insulating elements 100B may be respectively applied to a sprue pattern section 190 and gate-land pattern sections 200A1-200A4 (generally referenced as 200A) of a gate pattern section 130 of the wax assembly 140. Insulating sections may be required.
  • the insulating elements 100B are configured to provide for thermal control of the casting process by preventing heat from being drawn out of the molten material 180 ( FIGS. 6-7 ) applied during the casting process.
  • the thermal sink elements 100A may be formed from conductive material such as metal or ceramic (SiC).
  • the thermal sink elements 100A may have a higher thermal conductivity than the wax assembly 140 or a ceramic mold 150 (e.g., FIGS. 2-7 ) that is built around the wax assembly 140 as part of the casting process.
  • the thermal sink elements 100A may be attached directly to the part pattern section 120 of the wax assembly 140, to the ceramic mold 150, or to the gate pattern section 130 in close proximity to the part pattern section 120.
  • the thermal sink elements 100A may extract heat relatively quickly from the part pattern chamber 160 ( FIGS. 2-7 ) to provide a cast part 170 that is relatively sound and defect free.
  • the insulating elements 100B may be applied in similar fashion in the gate pattern section 130 to slow down the solidification process for fabricating the cast part 170.
  • the insulating elements 100B may be a ceramic with lower conductivity than the remainder of the ceramic mold 150.
  • the insulating elements 100B may be formed of a material such as monolithic ceramics such as alumina, zircon, silica, etc., or a thermal barrier ceramic with controlled thermal conductivity such as yttria stabilized zirconia (YSZ), or a ceramic matrix composite which can control heat retention or dissipation in a controlled manner .
  • YSZ yttria stabilized zirconia
  • the disclosed process utilizes the temperature control elements 100 in situ in the investment casting and solid mold casting processes to affect a natural solidification rate of the molten material 180 ( FIG. 8 and 9 ).
  • the temperature control elements 100 may do this by directing and removing latent heat. This optimizes the solidification the molten material 180 to form a cast part 170 in the part pattern chamber 160. This process may improve product yields and reduce scrap and rework.
  • FIG. 2 shows an investment casting mold assembly 165 and includes the wax assembly 140 encased in the ceramic mold 150 as part of an investment casting process.
  • FIG. 2 also shows the thermal sink elements 100A encased in the ceramic mold 150 and positioned against the part pattern section 120.
  • the figure shows the insulating elements 100B encased in the ceramic mold 150 and located against the sprue pattern section 190.
  • FIG. 3 shows a solid-mold casting assembly 165A and includes the wax assembly 140 encased in the ceramic mold 150 as part of a solid-mold casting process.
  • FIG. 3 also shows the thermal sink elements 100A encased in the ceramic mold 150 and located against the part pattern section 120.
  • the figure also shows the insulating elements 100B encased in the ceramic mold 150 and located against the sprue pattern section 190 and the gate-land pattern sections 200A.
  • FIG. 3 further shows the flask 230 for supporting the ceramic mold 150.
  • FIG. 4 shows the ceramic mold 150 with the wax assembly 140 removed as part of an investment casting process.
  • FIG. 4 also shows the thermal sink elements 100A at the part pattern chamber 160, the insulating elements 100B at the sprue 190A and the gate-lands 200B1-200B5 (generally referenced as 200B) formed by removal of the wax assembly 140.
  • FIG. 4 also shows the gate section 130A formed by removal of the wax assembly 140.
  • FIG. 5 shows the ceramic mold 150 with the wax assembly 140 removed as part of a solid-mold casting process.
  • FIG. 5 also shows the thermal sink elements 100A at the part pattern chamber 160 formed by removal of the wax assembly 140, and the insulating elements 100B at the sprue 190A the gate-lands 200B formed by removal of the wax assembly 140.
  • FIG. 5 further shows the gate section 130A formed by removal of the wax assembly 140 and the flask 230 for supporting the ceramic mold 150.
  • FIG. 6 shows the ceramic mold 150, including the sprue 190A, the gate section 130A and the part pattern chamber 160, filled with molten material 180 as part of an investment casting process.
  • FIG. 6 also shows the thermal sink elements 100A at the part pattern chamber 160 and the insulating elements 100B at the sprue 190A and the gate-lands 200B.
  • FIG. 7 shows the ceramic mold 150, including the sprue 190A, the gate section 130A and the part pattern chamber 160, filled with molten material 180 as part of a solid-mold casting process.
  • FIG. 7 also shows the thermal sink elements 100A at the part pattern chamber 160 and the insulating elements 100B at the sprue 190A and the gate-lands 200B.
  • FIG. 7 further shows the flask 230 for supporting the ceramic mold 150.
  • the insulating elements 100B prevent the molten material 180 from cooling and drying, e.g., at the sprue 190A and the gate-lands 200B.
  • the thermal sink elements 100A remove excess heat from molten material 180 in the part pattern chamber 160 adjacent to where it is placed. Thus, placing the thermal sink elements 100A next to a thicker portion of the part pattern chamber 160 enable cooling at a similar rate as a thinner portion of the part pattern chamber 160.
  • FIG. 8 shows the cast part 170 with the ceramic mold removed as part of either the investment casting process or the solid mold process. Excess metal 170A is around the cast part 170 in locations corresponding to the sprue 190A and gate section 130A (e.g., FIGS. 6-7 ).
  • FIG. 9 shows the cast part 170 in the final form, with the excess metal 170A removed.
  • FIG. 10 is a flowchart showing a lost-wax method of casting a part, i.e., to provide the cast part 170.
  • the method includes attaching the temperature control elements 100 to the wax assembly 140.
  • the method includes encasing the wax assembly 140 and the temperature control elements 100 in the ceramic mold 150.
  • the method includes removing the wax assembly 140 from the ceramic mold 150.
  • the method includes filling the ceramic mold 150 with molten material 180 to form the cast part 170 within the ceramic mold 150.
  • the method includes separating the ceramic mold 150 and the cast part 170 from each other.
  • the method may further include attaching the thermal sink elements 100A to the part pattern section 120 of the wax assembly 140.
  • the method may further include attaching the insulating elements 100B to the sprue pattern section 190 and the gate-land pattern sections 200A of the wax assembly 140.
  • the method may further include attaching steel blocks (as the thermal sink elements 100A) to the part pattern section of the wax assembly 140 to draw heat from the molten material 180.
  • the method may include positioning the thermal sink elements 100A closer to the first portions 210A of the part pattern section 120 of the wax assembly 140 than the second portions 220A of the part pattern section 120 of the wax assembly 140.
  • the first portions 210A are thicker than the second portions 220A.
  • the method may include positioning the thermal sink elements 100A about one or more of side, front and back surfaces 125A-125C of the wax assembly 140.
  • the method further includes attaching the temperature control elements 100 directly to the part pattern section 120 of the wax assembly 140.
  • the thermal sink elements 100A may be formed of metal having a melting temperature that is greater than the molten material 180.
  • the thermal sink elements 100A will remain solid and not contaminate the molten material 180.
  • the insulating elements 100B are also formed of a material that will not contaminate the molten material 180, and may be, e.g., a ceramic as indicated above.
  • the temperature control elements 100 may be attached the wax assembly 140 via, e.g., additional melted wax.
  • the method may include forming the ceramic mold 150 about the wax assembly 140 to a first thickness to define a first layer of the ceramic mold 150.
  • the method may include, as shown in block 240, attaching the temperature control elements 100 to the first layer of the ceramic mold 150.
  • a thin layer of ceramic may separate the temperature control elements 100 from the wax assembly 140. This minimizes a likelihood of cross contamination between the molten material 180 and either of the temperature control elements 100.
  • the method may further include forming the ceramic mold 150 about the wax assembly 140 to a second thickness that is greater than the first thickness. This action encases the temperature control elements 100 within the ceramic mold 150. With this configuration, the temperature control elements 100 are securely contained and structurally isolated within the ceramic mold 150.
  • the method may further include forming layers of the ceramic mold 150 to build-up the ceramic mold 150 to the second thickness. This action forms the ceramic mold 150 about the wax assembly 140.
  • Forming layers of the ceramic mold 150 may include encasing the wax assembly in a ceramic slurry, and drying the ceramic slurry, and repeating.
  • the method may further include positioning the wax assembly 140 in a flask 230.
  • the method may further include, as shown in block 280, filling the flask 230 with the ceramic slurry. This action forms the ceramic mold 150 about the wax assembly 140.
  • the method may include mechanically separating, e.g., with application of blunt force (or other mechanical action, such as the utilization of a hammer or other impact implement), the ceramic mold 150 and the cast part 170 from each other.
  • the method may further include thermally removing wax from and firing (e.g., applying fire or other similar heat source to) the ceramic mold 150 to sinter the ceramic and prepare the ceramic mold 150 for casting. Such heat treatment assists in strengthening the ceramic mold 150 so that it may withstand the temperature and the weight of the molten material 180.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
EP21172009.9A 2020-05-08 2021-05-04 Wärmemanagement beim wachsausschmelzguss Active EP3907018B1 (de)

Applications Claiming Priority (1)

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US202063022179P 2020-05-08 2020-05-08

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EP3907018A1 true EP3907018A1 (de) 2021-11-10
EP3907018B1 EP3907018B1 (de) 2023-03-29

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Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN115978336B (zh) * 2022-12-29 2025-06-20 重庆两航金属材料有限公司 一种含中空管道的铸件及其制备方法
CN117483666B (zh) * 2023-11-07 2024-05-24 东莞市五股机械有限公司 一种精密铸造用陶壳的制备方法

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2792771A1 (de) * 2013-04-19 2014-10-22 United Technologies Corporation Verfahren zur Herstellung von einkristallinen Bauteilen unter Verwendung einer Additivherstellung und Abschmelzen
US20170087626A1 (en) * 2015-09-30 2017-03-30 Crucible Intellectual Property, Llc Investment-diecasting mold
US9901976B2 (en) * 2015-07-29 2018-02-27 Castem Co., Ltd. Method for manufacturing casting using lost wax process
US20190358850A1 (en) * 2017-06-28 2019-11-28 General Electric Company Additively manufactured integrated casting core structure with ceramic shell

Family Cites Families (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
RU2634819C2 (ru) * 2013-01-18 2017-11-03 Немак Вернигероде Гмбх Способ литья и литейная форма со специальным питающим каналом для изготовления литых деталей, в частности, блоков цилиндров и головок цилиндров
US20160175666A1 (en) * 2014-12-18 2016-06-23 Taylor Made Golf Company, Inc. Investment-casting of thin-walled golf club-heads

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2792771A1 (de) * 2013-04-19 2014-10-22 United Technologies Corporation Verfahren zur Herstellung von einkristallinen Bauteilen unter Verwendung einer Additivherstellung und Abschmelzen
US9901976B2 (en) * 2015-07-29 2018-02-27 Castem Co., Ltd. Method for manufacturing casting using lost wax process
US20170087626A1 (en) * 2015-09-30 2017-03-30 Crucible Intellectual Property, Llc Investment-diecasting mold
US20190358850A1 (en) * 2017-06-28 2019-11-28 General Electric Company Additively manufactured integrated casting core structure with ceramic shell

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US20210346945A1 (en) 2021-11-11
EP3907018B1 (de) 2023-03-29

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