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EP1769862A1 - Procédé de fabrication d'un assemblage de noyau et de modèle perdu pour la coulée c'un corps creux - Google Patents

Procédé de fabrication d'un assemblage de noyau et de modèle perdu pour la coulée c'un corps creux Download PDF

Info

Publication number
EP1769862A1
EP1769862A1 EP06255099A EP06255099A EP1769862A1 EP 1769862 A1 EP1769862 A1 EP 1769862A1 EP 06255099 A EP06255099 A EP 06255099A EP 06255099 A EP06255099 A EP 06255099A EP 1769862 A1 EP1769862 A1 EP 1769862A1
Authority
EP
European Patent Office
Prior art keywords
pattern
self
cores
locating features
pattern half
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
EP06255099A
Other languages
German (de)
English (en)
Other versions
EP1769862B1 (fr
Inventor
Michael K. Turkington
John J. Marcin, Jr.
Steven J. Bullied
Lea D. Kennard
Carl R. Verner
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 EP1769862A1 publication Critical patent/EP1769862A1/fr
Application granted granted Critical
Publication of EP1769862B1 publication Critical patent/EP1769862B1/fr
Active legal-status Critical Current
Anticipated expiration legal-status Critical

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Classifications

    • 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
    • B22C7/023—Patterns made from expanded plastic materials
    • B22C7/026—Patterns made from expanded plastic materials by assembling preformed parts
    • 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
    • B22C9/10—Cores; Manufacture or installation of cores
    • B22C9/108—Installation of cores

Definitions

  • This disclosure relates to manufacturing hollow components and, more particularly, to manufacturing a pattern for hollow components.
  • a wax pattern of a component is produced.
  • the wax pattern is a replica of the component to the produced.
  • a number of wax patterns are assembled together on a wax gating tree to form a cluster or wax mold assembly.
  • the wax mold assembly is immersed in a liquid ceramic slurry which quickly gels after draining, strengthening refractory granules are sprinkled over the ceramic slurry covered wax mold assembly and the refractory granules bond to the slurry coating to produce a ceramic layer on the wax mold assembly.
  • This process is repeated several times to produce many ceramic layers on the wax mold assembly.
  • the wax is then melted out leaving a ceramic shell mold having an internal cavity identical in shape to that of the original wax cluster. This ceramic shell mold is called an investment casting mold.
  • the mold is fired at a high temperature to purify it by removing all traces of residual wax, while at the same time curing the ceramic shell mold.
  • the ceramic shell mold is then transferred to a casting furnace, which may be operated at either vacuum conditions or at atmospheric conditions.
  • a charge of molten metal is then poured into the ceramic shell mold and the mold is allowed to cool to room temperature, after which the ceramic shell mold is removed leaving the cast component or components.
  • the wax patterns of the hollow components are produced by injecting wax into a pattern die which has one or more preformed ceramic cores located therein.
  • the pattern die has shaped surfaces and the ceramic core is spaced from these shaped surfaces of the pattern die by supports, such as spacer supports, chaplets and the like, to ensure the correct thickness gap exists between the surfaces of the die and the ceramic core surfaces.
  • the ceramic core has shaped projections which locate in correspondingly shaped apertures in the pattern die. The combination of the projections and the supports prevent the ceramic cores from moving longitudinally in the pattern die by a precisely positioned pin and slot arrangement.
  • the supports fitted to the core are positioned to ensure that the correct thickness of wax is achieved.
  • the point load exerted onto the ceramic core by the supports actually strain the ceramic core while trying to correct the distorted shape against the restraint imposed by the shaped projections of the ceramic core locating in the corresponding shaped apertures in the pattern die.
  • the strain is enough to fracture the brittle ceramic core thus scrapping the wax pattern.
  • the strain is insufficient to break the ceramic core, there is a residual strain imposed in the ceramic core which, when the wax is removed from the ceramic shell mold, causes the ceramic core to spring back to its free state and subsequently produces a cast turbine blade or turbine vane which has a thin wall section.
  • a method for manufacturing a hollow component using a wax pattern with internal cores broadly comprises creating a first pattern half having one or more first self-locating features; creating a second pattern half having one or more second self-locating features; providing one or more cores; and assembling the pattern by engaging the one or more first self-locating features and the one or more second self-locating features about the one or more cores.
  • a pattern for a hollow component broadly comprises a first pattern half having one or more first self-locating features; a second pattern half having one or more second self-locating features; and one or more cores disposed in contact with the one or more first self-locating features and the one or more second self-locating features.
  • the wax pattern for a hollow component and its method of manufacture described herein facilitates the consistent placement and location of cores within the wax pattern.
  • the cores are not being subjected to wax injection pressures, the dimensions of the resultant hollow component are also ensured.
  • a first pattern half 10 comprises one or more first self-locating features 12 that may align with one or more cores 14.
  • the first self-locating features 12 may possess physical features that complement at least a portion, if not all of, the physical features of the cores 14.
  • the first self-locating features 12 complement the cores 14 such that the cores 14 are disposed within the self-locating features 12.
  • a second pattern half 16 may also comprise one or more second self-locating features 18 that may align with the cores 14.
  • the second self-locating features 18 may also possess physical features that complement at least a portion, if not all of, the physical features of the cores 14.
  • the second self-locating features 18 complement the cores 14 such that the cores 14 are disposed within the self-locating features 18.
  • the self-locating features 12, 18 may be either positive features, negative features or a combination of both positive and negative features.
  • second pattern half 16 may be may have positive self-locating features which facilitates combining second pattern half 16 with one or more cores 14 and engage in a direction indicated by an arrow 22 the first pattern half 10 having complementary, negative self-locating features.
  • the cores 14 are disposed between pattern halves 10, 16 and rest within the first self-locating features 12 and second self-locating features 18.
  • the wax pattern 20 may then be sealed at a parting surface between pattern halves 10, 16 and core exits using any number of methods known to one of ordinary skill in the art.
  • the wax pattern 20 may be sealed using a welding method known to one of ordinary skill in the art. In such an application, the weld seam would then be blended as known to one of ordinary skill in the art.
  • the cores 14 are shown disposed within the self-locating features 12, 18 and between the two halves 10, 16. It is contemplated that the self-locating features 12, 18 may be formed at various angles through each pattern half 10, 16 such that one or more cores 14 may be disposed at an angle to each pattern half 10, 16 within their self-locating features 12, 18, respectively. It is also contemplated that one or more additional pieces may be added, e.g., a layered pattern may be manufactured having several pieces stacked one on top the other rather than only two halves being employed. Also, as more pieces are used to form the pattern or large pieces are used to form the pattern, additional self-locating features may be incorporated to facilitate the connection between the parts as well as the cores rather than the cores alone.
  • the wax pattern 20 of a component having a hollow interior may comprise a first pattern half 10, a second pattern half 16 and one or more cores 14 disposed therein.
  • Each pattern half 10, 16 defines the external shape of the wax pattern of the hollow component and may comprise any material suitable for withstanding the operating conditions of a typical casting process as known to one of ordinary skill in the art.
  • the cores 14 may comprise any ceramic material or refractory metal suitable for use in typical casting processes as known to one of ordinary skill in the art. Suitable ceramic materials may include, but are not limited to, silica, alumina, zirconia, combinations comprising at least one of the foregoing, and the like. Suitable refractory metals may include, but are not limited to, molybdenum, tungsten, combinations comprising at least one of the foregoing, and the like.
  • the hollow component formed by wax pattern 20 may be a turbine engine component such as a turbine engine blade or vane.
  • One pattern half may define the convex airfoil shaped surface of a pattern of a hollow turbine engine blade or vane.
  • the other pattern half may similarly define the concave airfoil shaped surface of a pattern of the hollow turbine engine blade or vane.
  • the cores may define the internal shape of the pattern of the hollow turbine engine component.
  • the core may possess a convex airfoil shaped surface and a concave airfoil shaped surface. It is contemplated though that the method(s) and resulting pattern described herein may be utilized in practically any industry that casts to hollow, thin walled components.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
EP06255099A 2005-10-03 2006-10-03 Procédé de fabrication d'un objet creux par coulée utilisant un noyau comprenant des modèles à la cire perdue pour la coulée c'un corps creux Active EP1769862B1 (fr)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US11/242,527 US20070074839A1 (en) 2005-10-03 2005-10-03 Method for manufacturing a pattern for a hollow component

Publications (2)

Publication Number Publication Date
EP1769862A1 true EP1769862A1 (fr) 2007-04-04
EP1769862B1 EP1769862B1 (fr) 2011-09-07

Family

ID=37711324

Family Applications (1)

Application Number Title Priority Date Filing Date
EP06255099A Active EP1769862B1 (fr) 2005-10-03 2006-10-03 Procédé de fabrication d'un objet creux par coulée utilisant un noyau comprenant des modèles à la cire perdue pour la coulée c'un corps creux

Country Status (5)

Country Link
US (1) US20070074839A1 (fr)
EP (1) EP1769862B1 (fr)
JP (1) JP2007098476A (fr)
CN (1) CN1943909A (fr)
SG (1) SG131010A1 (fr)

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2316593A3 (fr) * 2009-10-28 2012-01-18 Howmet Corporation Outillage de noyau fugitif et procédé
US9284846B2 (en) 2009-05-20 2016-03-15 Howmet Corporation Pt-Al-Hf/Zr coating and method
US9835035B2 (en) 2013-03-12 2017-12-05 Howmet Corporation Cast-in cooling features especially for turbine airfoils

Families Citing this family (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US8240999B2 (en) * 2009-03-31 2012-08-14 United Technologies Corporation Internally supported airfoil and method for internally supporting a hollow airfoil during manufacturing
CN103157763A (zh) * 2011-12-16 2013-06-19 洛阳奇润电力科技有限公司 尿素芯和陶瓷芯的应用方法
US9845728B2 (en) 2015-10-15 2017-12-19 Rohr, Inc. Forming a nacelle inlet for a turbine engine propulsion system
CN106424587B (zh) * 2016-10-20 2018-05-22 苏州东吴黄金文化发展有限公司 一种素金空心路路通的制作方法
US11433990B2 (en) 2018-07-09 2022-09-06 Rohr, Inc. Active laminar flow control system with composite panel

Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3635280A (en) * 1969-11-07 1972-01-18 John T Parsons Self-aligned multipart combustible casting pattern and method of making same
US3695340A (en) * 1970-05-04 1972-10-03 Parsons John T Multi-part combustible casting pattern having bend-resistant glue-less joints
US3965963A (en) * 1973-11-16 1976-06-29 United Technologies Corporation Mold and process for casting high temperature alloys
US3981344A (en) * 1974-08-21 1976-09-21 United Technologies Corporation Investment casting mold and process
US4068702A (en) * 1976-09-10 1978-01-17 United Technologies Corporation Method for positioning a strongback
US4078598A (en) * 1976-09-10 1978-03-14 United Technologies Corporation Strongback and method for positioning same
EP0559251A1 (fr) * 1992-02-18 1993-09-08 General Motors Corporation Procédé pour la production des structure coulées, à paroi mince avec une résistance à chaud élevée
WO2000032331A1 (fr) * 1998-12-01 2000-06-08 Howmet Research Corporation Ensemble noyau a pieces multiples

Family Cites Families (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB9203585D0 (en) * 1992-02-20 1992-04-08 Rolls Royce Plc An assembly for making a pattern of a hollow component
JP2902379B2 (ja) * 1997-04-25 1999-06-07 三菱製鋼株式会社 ワックスパターンの製作方法
KR100684061B1 (ko) * 1999-07-28 2007-02-16 소니 가부시끼 가이샤 기록 시스템, 데이터 기록 장치, 메모리 장치 및 데이터기록 방법
ATE350182T1 (de) * 1999-10-26 2007-01-15 Howmet Res Corp Mehrwandiger kern und verfahren
US7048030B1 (en) * 2004-11-19 2006-05-23 Deere & Company Method of making a casting assembly

Patent Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3635280A (en) * 1969-11-07 1972-01-18 John T Parsons Self-aligned multipart combustible casting pattern and method of making same
US3695340A (en) * 1970-05-04 1972-10-03 Parsons John T Multi-part combustible casting pattern having bend-resistant glue-less joints
US3965963A (en) * 1973-11-16 1976-06-29 United Technologies Corporation Mold and process for casting high temperature alloys
US3981344A (en) * 1974-08-21 1976-09-21 United Technologies Corporation Investment casting mold and process
US4068702A (en) * 1976-09-10 1978-01-17 United Technologies Corporation Method for positioning a strongback
US4078598A (en) * 1976-09-10 1978-03-14 United Technologies Corporation Strongback and method for positioning same
EP0559251A1 (fr) * 1992-02-18 1993-09-08 General Motors Corporation Procédé pour la production des structure coulées, à paroi mince avec une résistance à chaud élevée
WO2000032331A1 (fr) * 1998-12-01 2000-06-08 Howmet Research Corporation Ensemble noyau a pieces multiples

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US9284846B2 (en) 2009-05-20 2016-03-15 Howmet Corporation Pt-Al-Hf/Zr coating and method
US9404372B2 (en) 2009-05-20 2016-08-02 Howmet Corporation Pt-Al-Hf/Zr coating and method
EP2316593A3 (fr) * 2009-10-28 2012-01-18 Howmet Corporation Outillage de noyau fugitif et procédé
US9835035B2 (en) 2013-03-12 2017-12-05 Howmet Corporation Cast-in cooling features especially for turbine airfoils

Also Published As

Publication number Publication date
JP2007098476A (ja) 2007-04-19
US20070074839A1 (en) 2007-04-05
SG131010A1 (en) 2007-04-26
CN1943909A (zh) 2007-04-11
EP1769862B1 (fr) 2011-09-07

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