EP1595618B1 - Lost wax pattern moulding process with contact layer - Google Patents
Lost wax pattern moulding process with contact layer Download PDFInfo
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- EP1595618B1 EP1595618B1 EP05103895A EP05103895A EP1595618B1 EP 1595618 B1 EP1595618 B1 EP 1595618B1 EP 05103895 A EP05103895 A EP 05103895A EP 05103895 A EP05103895 A EP 05103895A EP 1595618 B1 EP1595618 B1 EP 1595618B1
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- contact layer
- slip
- layer
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- 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
Definitions
- the present invention relates to the manufacture of parts such as metal vanes with complex geometries according to the technique known as lost-wax foundry.
- turbofan bladders such as parts of rotors or stators, or structural parts according to this technique
- it is first made a model wax or other equivalent material easily removable later. If necessary, we group together several models into one cluster.
- a ceramic mold is made around this model by dipping in a first slip to form a first layer of material in contact with its surface. The surface of this layer is sanded in order to reinforce it and facilitate the attachment of the next layer, and the assembly is dried: this constitutes the stuccage and drying operations respectively.
- the soaking operation is then repeated in slips of possibly different compositions, an operation always associated with the successive operations of stuccage and drying.
- a ceramic shell made of a plurality of layers is thus produced.
- the slips are composed of particles of ceramic materials, in particular a flour, such as alumina, mullite, zircon or other, with a mineral colloidal binder and adjuvants where appropriate depending on the desired rheology.
- a flour such as alumina, mullite, zircon or other
- adjuvants where appropriate depending on the desired rheology.
- It may be a wetting agent, a fluidizer or a texturizer depending, for the latter, the desired thickness for the deposit.
- the carapace mold is then dewaxed, which is an operation by which the material constituting the original model is removed. After elimination of the model, we obtain a ceramic mold whose cavity reproduces all the details of the model. The mold then undergoes heat treatment at high temperature or "cooking" which gives it the necessary mechanical properties. The shell mold is thus ready for the manufacture of the metal part by casting.
- the next step is to sink a molten metal into the mold cavity and then to solidify it.
- solidification techniques there are currently several solidification techniques, and therefore several casting techniques, depending on the nature of the alloy and the expected properties of the part resulting from the casting. It may be directed solidification with columnar structure (DS), directed solidification with monocrystalline structure (SX) or equiaxed solidification (EX) respectively.
- DS columnar structure
- SX monocrystalline structure
- EX equiaxed solidification
- the shell is broken by a shake-out operation, and the manufacturing of the metal part is completed.
- each carapace must have specific properties that ensure the desired type of solidification.
- the shells can be made from different fillers, based on silico-aluminous, silica-zircon or silica.
- the first layer for each of these carapaces plays a vital role. It forms the interface between the shell mold and the cast alloy. It must, in the case of a solidification directed columnar or monocrystalline structure, be non-reactive with the cast alloy. In the case of equiaxial solidification, it must allow the equiaxial germination of the grains. Furthermore, the integrity of this contact layer determines the final quality of the casting, in terms of surface condition in particular.
- the first layer must meet certain requirements in order to avoid defects such as ceramic decohesion and surface defects.
- the decohesions of the contact layer before or during the casting can generate harmful marks on parts.
- the surface defects result from excessive micro-porosity of the contact layer which generates surpluses forming reliefs on the surface of the parts.
- the major surface defects are often the result of a surface capillary phenomenon at the interface between the wax model and the first layer.
- the grains of sand form stacks, which have many capillaries.
- the depression promotes a capillary rise of the slip towards the stucco until the column of liquid thus formed restores the pressure difference. This results in the formation of a cavity withdrawal zone which leads to the formation of surface defects. This phenomenon is accentuated by a first layer of too low thickness.
- the properties of the contact layer must therefore make it possible to find a compromise between these antagonistic characteristics, in order to overcome any defects on parts.
- the composition of the slip it is possible to fulfill the objectives assigned for all foundry molds, the properties of which satisfy the casting conditions in particular meeting the constraints of solidification processes DS and SX.
- the contact layer is not reactive to cast superalloys.
- the slip is advantageously composed of mullite flour in an amount of between 65 and 90% by weight, without zircon.
- the sand particles or "stuccos" for this contact layer are formed from mullite and not zircon grains.
- additives in the slip allows to control wax deposits and ensure optimal characteristics in terms of thickness and distribution on parts.
- the binder is a water-based mineral colloidal solution, such as colloidal silica, and not an alcohol base binder.
- the method of manufacturing the shell molds comprises a first step of manufacturing the model in wax or in another equivalent material known in the field.
- the most commonly known is wax.
- the cluster models can be grouped so that they can be simultaneously.
- the models are shaped to the dimensions of the final pieces, to the shrinkage near the alloys.
- the carapace manufacturing steps are preferably carried out by a robot whose movements are programmed to have an optimal action on the quality of the deposits made, and to overcome the geometric aspect of the various blades.
- slips are prepared in which the models or the cluster are quenched successively to deposit ceramic materials.
- the covered model undergoes a phase of dewatering and then topping.
- Sand stucco grains are then sprinkled to avoid disturbing the thin layer of contact.
- Mullite is used, the particle size of which in this first layer is fine. It is between 80 and 250 microns. The surface condition of the final pieces depends in part.
- the layer is dried.
- the dipping is then carried out in a second slip to form a so-called "intermediate" layer.
- the model is then quenched in a third slip to form the layer 3 which is the first so-called "reinforcing" layer.
- the stucco is then applied and dried.
- the soaking operations are repeated in the third slip, stucco and drying to obtain the desired shell thickness.
- a glazing operation is carried out for the last layer.
- the second and third slip may comprise a mixture of alumina and mullite flours in amounts of from 45 to 95% by weight, and mullite grains in amounts of from 0 to 25% by weight.
- the soaked layers for the different layers are made in different ways and adapted to obtain a uniform distribution of thicknesses and to avoid the formation of bubbles, especially in enclosed areas.
- the carapace can thus comprise from 5 to 12 layers.
- the baking cycle of the molds comprises a temperature rise phase during a given period, a plateau at the baking temperature and a cooling phase.
- the firing cycle is chosen to optimize the mechanical properties of the shells so as to allow cold handling without risk of breakage, and so as to minimize their sensitivity to thermal shocks that can be generated during the various stages of casting.
- This contact layer can be associated with all types of layers as required, even if necessary with layers made from zircon particles.
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Description
La présente invention porte sur la fabrication de pièces telles que des aubages métalliques à géométries complexes selon la technique connue sous le nom de fonderie à cire perdue.The present invention relates to the manufacture of parts such as metal vanes with complex geometries according to the technique known as lost-wax foundry.
Pour la fabrication des aubages de turboréacteurs, tels que les pièces de rotors ou de stators, ou bien des pièces de structure selon cette technique, on en réalise d'abord un modèle en cire ou autre matériau équivalent facilement éliminable par la suite. Le cas échéant, on regroupe plusieurs modèles en une grappe. On confectionne autour de ce modèle un moule céramique par trempage dans une première barbotine pour former une première couche de matière au contact de sa surface. On sable la surface de cette couche afin de la renforcer et de faciliter l'accrochage de la couche suivante, et on sèche l'ensemble : ce qui constitue respectivement les opérations de stuccage et de séchage. On répète ensuite l'opération de trempage dans des barbotines de compositions éventuellement différentes, opération toujours associée aux opérations successives de stuccage et de séchage. On réalise ainsi une carapace céramique constituée d'une pluralité de couches. Les barbotines sont composées de particules de matériaux céramiques, notamment une farine, tel que l'alumine, la mullite, le zircon ou autre, avec un liant colloïdal minéral et des adjuvants le cas échéant en fonction de la rhéologie souhaitée. Ces adjuvants permettent de maîtriser et de stabiliser les caractéristiques des différents types de couches, tout en s'affranchissant des effets des différentes caractéristiques physicochimiques des matières premières constituant les barbotines. Il peut s'agir d'un agent mouillant, d'un fluidifiant ou d'un texturant en fonction, pour ce dernier, de l'épaisseur désirée pour le dépôt.For the manufacture of turbofan bladders, such as parts of rotors or stators, or structural parts according to this technique, it is first made a model wax or other equivalent material easily removable later. If necessary, we group together several models into one cluster. A ceramic mold is made around this model by dipping in a first slip to form a first layer of material in contact with its surface. The surface of this layer is sanded in order to reinforce it and facilitate the attachment of the next layer, and the assembly is dried: this constitutes the stuccage and drying operations respectively. The soaking operation is then repeated in slips of possibly different compositions, an operation always associated with the successive operations of stuccage and drying. A ceramic shell made of a plurality of layers is thus produced. The slips are composed of particles of ceramic materials, in particular a flour, such as alumina, mullite, zircon or other, with a mineral colloidal binder and adjuvants where appropriate depending on the desired rheology. These adjuvants make it possible to control and stabilize the characteristics of the different types of layers, while avoiding the effects of the different physicochemical characteristics of the raw materials constituting the slips. It may be a wetting agent, a fluidizer or a texturizer depending, for the latter, the desired thickness for the deposit.
On procède ensuite au décirage du moule carapace, qui est une opération par laquelle on élimine le matériau constituant le modèle d'origine. Après élimination du modèle, on obtient un moule céramique dont la cavité reproduit tous les détails du modèle. Le moule subit ensuite un traitement thermique à haute température ou « cuisson » qui lui confère les propriétés mécaniques nécessaires. Le moule carapace est ainsi prêt pour la fabrication de la pièce métallique par coulée.The carapace mold is then dewaxed, which is an operation by which the material constituting the original model is removed. After elimination of the model, we obtain a ceramic mold whose cavity reproduces all the details of the model. The mold then undergoes heat treatment at high temperature or "cooking" which gives it the necessary mechanical properties. The shell mold is thus ready for the manufacture of the metal part by casting.
Après contrôle de l'intégrité interne et externe du moule carapace, l'étape suivante consiste à couler un métal en fusion dans la cavité du moule puis à le solidifier. Dans le domaine de la fonderie à cire perdue, on distingue actuellement plusieurs techniques de solidification, donc plusieurs techniques de coulée, selon la nature de l'alliage et les propriétés attendues de la pièce résultant de la coulée. Il peut s'agir de solidification dirigée à structure colonnaire (DS), de solidification dirigée à structure monocristalline (SX) ou de solidification équiaxe (EX) respectivement. Les deux premières familles de pièces concernent des superalliages pour des pièces soumises à de fortes contraintes, tant thermiques que mécaniques dans le turboréacteur, comme les aubes de turbines HP.After checking the internal and external integrity of the shell mold, the next step is to sink a molten metal into the mold cavity and then to solidify it. In the field of lost-wax foundry, there are currently several solidification techniques, and therefore several casting techniques, depending on the nature of the alloy and the expected properties of the part resulting from the casting. It may be directed solidification with columnar structure (DS), directed solidification with monocrystalline structure (SX) or equiaxed solidification (EX) respectively. The first two families of parts concern superalloys for parts subjected to high stresses, both thermal and mechanical in the turbojet engine, such as HP turbine blades.
Après la coulée de l'alliage, on casse la carapace par une opération de décochage, et on parachève la fabrication de la pièce métallique.After the casting of the alloy, the shell is broken by a shake-out operation, and the manufacturing of the metal part is completed.
Lors de l'étape de moulage, plusieurs types de carapaces peuvent être réalisés au travers de plusieurs procédés. Chaque carapace doit posséder des propriétés spécifiques qui permettent d'assurer le type de solidification désiré.During the molding step, several types of shells can be made through several processes. Each carapace must have specific properties that ensure the desired type of solidification.
Par exemple, pour la solidification équiaxe, plusieurs procédés différents peuvent être mis en oeuvre, l'un utilisant un liant à base de silicate d'éthyle, un autre utilisant un liant à base de silice colloïdale. Pour la solidification dirigée, les carapaces peuvent être réalisées à partir de charges différentes, à base silico-alumineuse, silice-zircon ou silice.For example, for equiaxed solidification, several different processes can be implemented, one using an ethyl silicate binder, another using a colloidal silica binder. For directed solidification, the shells can be made from different fillers, based on silico-aluminous, silica-zircon or silica.
La première couche pour chacune de ces carapaces joue un rôle essentiel. Elle constitue l'interface entre le moule carapace et l'alliage coulé. Elle doit, dans le cas d'une solidification dirigée à structure colonnaire ou monocristalline, être non réactive avec l'alliage coulé. Dans le cas d'une solidification équiaxe, elle doit permettre la germination équiaxe des grains. Par ailleurs, l'intégrité de cette couche de contact détermine la qualité finale de la pièce coulée, en terme d'état de surface notamment.The first layer for each of these carapaces plays a vital role. It forms the interface between the shell mold and the cast alloy. It must, in the case of a solidification directed columnar or monocrystalline structure, be non-reactive with the cast alloy. In the case of equiaxial solidification, it must allow the equiaxial germination of the grains. Furthermore, the integrity of this contact layer determines the final quality of the casting, in terms of surface condition in particular.
La première couche doit en effet satisfaire à certaines exigences afin d'éviter des défauts tels que les décohésions céramiques, et les défauts de surface.The first layer must meet certain requirements in order to avoid defects such as ceramic decohesion and surface defects.
Les décohésions de la couche de contact avant ou pendant la coulée, peuvent générer des marques néfastes sur pièces.The decohesions of the contact layer before or during the casting, can generate harmful marks on parts.
Les défauts surfaciques résultent d'une micro porosité excessive de la couche de contact qui génère des surplus formant des reliefs en surface des pièces.The surface defects result from excessive micro-porosity of the contact layer which generates surpluses forming reliefs on the surface of the parts.
Les défauts surfaciques majeurs sont souvent la résultante d'un phénomène capillaire surfacique à l'interface entre le modèle en cire et la première couche. Après trempé de la première couche, lors du saupoudrage, les grains de sable forment des empilements, lesquels présentent de nombreux capillaires. Chacun agit comme une ventouse qui donne lieu à une dépression. Celle-ci est d'autant plus grande que le capillaire est petit. Cela correspond à une première couche d'épaisseur insuffisante. La dépression favorise une ascension capillaire de la barbotine vers le stucco et ce, jusqu'à ce que la colonne de liquide ainsi formée rétablisse la différence de pression. Il s'ensuit la formation d'une zone de retrait avec cavité qui conduit à la formation de défauts surfaciques. Ce phénomène est accentué par une première couche d'épaisseur trop faible.The major surface defects are often the result of a surface capillary phenomenon at the interface between the wax model and the first layer. After dipping the first layer, during dusting, the grains of sand form stacks, which have many capillaries. Everyone acts like a sucker that gives rise to a depression. This is all the greater as the capillary is small. This corresponds to a first layer of insufficient thickness. The depression promotes a capillary rise of the slip towards the stucco until the column of liquid thus formed restores the pressure difference. This results in the formation of a cavity withdrawal zone which leads to the formation of surface defects. This phenomenon is accentuated by a first layer of too low thickness.
Ces deux types de défauts, majeurs en fonderie, sont liés à des caractéristiques antagonistes intrinsèques de la couche de contact. En effet, pour éviter les défauts de décohésions céramiques on tend vers un dépôt de première couche fin et uniforme, alors que pour éviter les défauts surfaciques on vise plutôt un dépôt de première couche uniforme mais plus épais.These two types of defects, major foundry, are related intrinsic antagonistic characteristics of the contact layer. Indeed, to avoid the defects of ceramic decohesion is tending to a deposition of first thin and uniform layer, while to avoid surface defects is rather a deposition first uniform but thicker layer.
Les propriétés de la couche de contact doivent donc permettre de trouver un compromis entre ces caractéristiques antagonistes, afin de s'affranchir de tous défauts sur pièces.The properties of the contact layer must therefore make it possible to find a compromise between these antagonistic characteristics, in order to overcome any defects on parts.
L'invention parvient à ces objectifs avec le procédé conforme aux caractéristiques de la revendication 1.The invention achieves these objectives with the method according to the features of claim 1.
Grâce à la composition de la barbotine, on parvient à remplir les objectifs assignés pour tous les moules de fonderie, dont les propriétés satisfont aux conditions de coulées répondant notamment aux contraintes des procédés de solidification DS et SX. En particulier, la couche de contact n'est pas réactive face aux superalliages coulés.Thanks to the composition of the slip, it is possible to fulfill the objectives assigned for all foundry molds, the properties of which satisfy the casting conditions in particular meeting the constraints of solidification processes DS and SX. In particular, the contact layer is not reactive to cast superalloys.
On connaît
Pour satisfaire aux contraintes économiques liées aux rejets, la barbotine est avantageusement composée de farine de mullite en quantité comprise entre 65 et 90% en poids, sans zircon. De même, les particules de sable ou « stuccos », pour cette couche de contact, sont formées à partir de grains de mullite et non de zircon.To satisfy the economic constraints related to rejects, the slip is advantageously composed of mullite flour in an amount of between 65 and 90% by weight, without zircon. Similarly, the sand particles or "stuccos" for this contact layer are formed from mullite and not zircon grains.
L'ajout des adjuvants dans la barbotine permet de maîtriser les dépôts sur cire et d'en assurer des caractéristiques optimales en terme d'épaisseurs et de répartition sur pièces.The addition of additives in the slip allows to control wax deposits and ensure optimal characteristics in terms of thickness and distribution on parts.
De préférence et pour satisfaire aux contraintes environnementales, le liant est une solution colloïdale minérale base eau, telle que la silice colloïdale, et non un liant base alcool.Preferably and to meet environmental requirements, the binder is a water-based mineral colloidal solution, such as colloidal silica, and not an alcohol base binder.
Le dépôt de couche de contact sur cire, associé à un renfort par saupoudrage d'un sable de mullite de granulométrie comprise entre 80 et 250 microns permet d'obtenir une très bonne cohésion de première couche et de très bons états de surface des pièces coulées.The deposition of the contact layer on wax, combined with a sprinkling reinforcement of a mullite sand with a particle size of between 80 and 250 microns, makes it possible to obtain a very good first-layer cohesion and very good surface conditions of the castings. .
On décrit ci-après le procédé plus en détail.The process is described in more detail below.
Le procédé de fabrication des moules carapaces comprend une première étape de fabrication du modèle en cire ou en un autre matériau équivalent connu dans le domaine. Le plus généralement connu est la cire. Selon le type de pièce, on peut regrouper les modèles en grappe de manière à pouvoir en fabriquer plusieurs simultanément. Les modèles sont façonnés aux dimensions des pièces définitives, au retrait près des alliages.The method of manufacturing the shell molds comprises a first step of manufacturing the model in wax or in another equivalent material known in the field. The most commonly known is wax. Depending on the type of part, the cluster models can be grouped so that they can be simultaneously. The models are shaped to the dimensions of the final pieces, to the shrinkage near the alloys.
Les étapes de fabrication de la carapace sont de préférence menées par un robot dont les mouvements sont programmés pour avoir une action optimale sur la qualité des dépôts réalisés, et pour s'affranchir de l'aspect géométrique des différents aubages.The carapace manufacturing steps are preferably carried out by a robot whose movements are programmed to have an optimal action on the quality of the deposits made, and to overcome the geometric aspect of the various blades.
On prépare parallèlement des barbotines dans lesquelles on trempe successivement les modèles ou la grappe pour effectuer des dépôts de matières céramiques.In parallel, slips are prepared in which the models or the cluster are quenched successively to deposit ceramic materials.
La composition de la première barbotine en pourcentage pondéral est la suivante :
- farine de mullite 65 - 80
- liant silice colloïdale 20 - 35
- eau 0-5
- 3 adjuvants organiques qui sont des agents respectivement mouillant, fluidifiant et texturant.
- mullite flour 65 - 80
- colloidal silica binder 20 - 35
- water 0-5
- 3 organic adjuvants which are respectively wetting, thinning and texturing agents.
Les 3 adjuvants ont respectivement les fonctions suivantes :
- Le fluidifiant permet d'obtenir plus rapidement la rhéologie désirée lors de la fabrication de la couche. Il agit en tant que dispersant. Il est choisi de préférence parmi les composés suivants : acides aminés, polyacrylates d'ammonium, tri-acides carboxyliques à groupements alcools.
- Le mouillant permet de faciliter le nappage de la couche lors du trempé. Il est de préférence choisi parmi les composés suivants : alcools gras poly-alkylènes, alcools alkoxylates.
- Le texturant permet d'optimiser la rhéologie de la couche afin d'obtenir des dépôt adaptés. Il est choisi de préférence parmi : les polymères de l'oxyde d'éthylène, les gommes de xanthane ou les gommes de guar.
- The fluidizer makes it possible to obtain the desired rheology more quickly during the manufacture of the layer. It acts as a dispersant. It is preferably chosen from the following compounds: amino acids, ammonium polyacrylates, tri-carboxylic acids with alcohol groups.
- The wetting agent makes it easier to coat the layer during dipping. It is preferably chosen from the following compounds: polyalkylene fatty alcohols, alkoxylated alcohols.
- The texturizer makes it possible to optimize the rheology of the layer in order to obtain suitable deposits. It is preferably chosen from: polymers of ethylene oxide, xanthan gums or guar gums.
Une fois le modèle retiré de la première barbotine après une phase d'immersion, le modèle recouvert subit une phase d'égouttage puis de nappage. On applique ensuite des grains de « stucco », particules de sable, par saupoudrage afin de ne pas perturber la fine couche de contact. On utilise de la mullite dont la granulométrie dans cette première couche est fine. Elle est comprise entre 80 et 250 microns. L'état de surface des pièces en final en dépend en partie.Once the model removed from the first slip after an immersion phase, the covered model undergoes a phase of dewatering and then topping. Sand stucco grains are then sprinkled to avoid disturbing the thin layer of contact. Mullite is used, the particle size of which in this first layer is fine. It is between 80 and 250 microns. The surface condition of the final pieces depends in part.
On sèche la couche.The layer is dried.
Les essais ont montré que pour obtenir des caractéristiques rhéologiques satisfaisantes, l'incorporation d'adjuvants était avantageuse sinon nécessaire.The tests have shown that to obtain satisfactory rheological characteristics, the incorporation of adjuvants was advantageous if not necessary.
On procède ensuite au trempé dans une seconde barbotine pour former une couche dite « intermédiaire ».The dipping is then carried out in a second slip to form a so-called "intermediate" layer.
Comme précédemment, on dépose un « stucco » et on sèche.As before, a "stucco" is deposited and dried.
On trempe ensuite le modèle dans une troisième barbotine pour former la couche 3 qui est la première couche dite « de renfort ».The model is then quenched in a third slip to form the layer 3 which is the first so-called "reinforcing" layer.
On applique ensuite le stucco et on sèche. On répète les opérations de trempage dans la troisième barbotine, de stuccage et de séchage pour obtenir l'épaisseur de carapace souhaitée. Pour la dernière couche, on procède à une opération de glaçage.The stucco is then applied and dried. The soaking operations are repeated in the third slip, stucco and drying to obtain the desired shell thickness. For the last layer, a glazing operation is carried out.
Les deuxième et troisième barbotines peuvent comprendre un mélange de farines d'alumine et de mullite en quantités comprises entre 45 et 95% en poids, et des grains de mullite en quantités comprises entre 0 et 25% en poids.The second and third slip may comprise a mixture of alumina and mullite flours in amounts of from 45 to 95% by weight, and mullite grains in amounts of from 0 to 25% by weight.
Les trempés pour les différentes couches sont effectués de manières différentes et adaptées afin d'obtenir une répartition homogène des épaisseurs et d'éviter la formation de bulles, notamment dans les zones enfermées.The soaked layers for the different layers are made in different ways and adapted to obtain a uniform distribution of thicknesses and to avoid the formation of bubbles, especially in enclosed areas.
On procède à un séchage final après la formation de la dernière couche.Final drying is carried out after the formation of the last layer.
La carapace peut ainsi comprendre de 5 à 12 couches.The carapace can thus comprise from 5 to 12 layers.
Le cycle de cuisson des moules comprend une phase de montée en température pendant une période déterminée, un palier à la température de cuisson et une phase de refroidissement. Le cycle de cuisson est choisi pour optimiser les propriétés mécaniques des carapaces de manière à permettre les manipulations à froid sans risque de casses, et de manière à minimiser leurs sensibilités aux chocs thermiques pouvant être générés lors des différentes étapes de coulées.The baking cycle of the molds comprises a temperature rise phase during a given period, a plateau at the baking temperature and a cooling phase. The firing cycle is chosen to optimize the mechanical properties of the shells so as to allow cold handling without risk of breakage, and so as to minimize their sensitivity to thermal shocks that can be generated during the various stages of casting.
On a décrit un exemple de procédé de fabrication de moule carapace à partir de la couche de contact selon l'invention. Cette couche de contact peut être associée à tous les types de couches selon les besoins, même le cas échéant avec des couches réalisées à partir de particules de zircon.An example of a method for manufacturing a shell mold from the contact layer according to the invention has been described. This contact layer can be associated with all types of layers as required, even if necessary with layers made from zircon particles.
Claims (10)
- A method of manufacture of a multilayer ceramic shell mould whereof at least one contact layer out of a wax master pattern or a part to be manufactured, or other similar material, consisting in dipping the master pattern in a first slip containing ceramic particles and a binder, in order to form said contact layer, in depositing the sable particles onto said layer and in drying said contact layer, characterised in that the ceramic particles of the first slip are mullite particles, the slip comprises a wetting agent, a liquefier and a texturing agent, the granulometry of said particles being comprised between 80 and 250 microns.
- A method according to claim 1 wherein the ceramic particles do not contain any zircon.
- A method according to claim 1 whereof the wetting agent is selected among polyalkylene fat alcohols or alkoxylate alcohols.
- A method according to claim 3 whereof the liquefier is selected among the amino acids, ammonium polyacrylates or carboxylic tri-acids with alcohol groups.
- A method according to claim 1 whereof the texturing agent is selected among ethylene oxide polymers, xanthan gums or guar gums.
- A method according to claim 1 whereof the binder is based on water-based mineral colloïdal solutions, in particular colloïdal silica.
- A method according to claim 1 whereof the sand particles are applied by sprinkling.
- A method according to claim 1, whereof the slip comprises mullite flour in an amount ranging between 65 and 80 % in weight.
- A usage of a shell mould according to one of the previous claims for the manufacture of a part with columnar structure oriented solidification.
- A usage of a shell mould according to one of the claims 1 to 8 for the manufacture of a turbomachine blade with mono-crystalline structure oriented solidification.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| FR0405145 | 2004-05-12 | ||
| FR0405145A FR2870148B1 (en) | 2004-05-12 | 2004-05-12 | LOST WAX FOUNDRY PROCESS WITH CONTACT LAYER |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| EP1595618A1 EP1595618A1 (en) | 2005-11-16 |
| EP1595618B1 true EP1595618B1 (en) | 2010-11-24 |
Family
ID=34939771
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| EP05103895A Expired - Lifetime EP1595618B1 (en) | 2004-05-12 | 2005-05-10 | Lost wax pattern moulding process with contact layer |
Country Status (6)
| Country | Link |
|---|---|
| US (1) | US7370688B2 (en) |
| EP (1) | EP1595618B1 (en) |
| JP (1) | JP4918227B2 (en) |
| CA (1) | CA2507171C (en) |
| DE (1) | DE602005024887D1 (en) |
| FR (1) | FR2870148B1 (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE102016123051A1 (en) * | 2016-11-29 | 2018-05-30 | HÜTTENES-ALBERTUS Chemische Werke Gesellschaft mit beschränkter Haftung | Amino acid-containing molding material mixture for the production of moldings for the foundry industry |
Families Citing this family (7)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN103561789A (en) * | 2011-07-29 | 2014-02-05 | 帝斯曼知识产权资产管理有限公司 | Medical devices containing wetted hydrophilic coatings |
| CN107199309B (en) * | 2017-06-08 | 2020-02-07 | 淄博金东机械制造有限公司 | Casting module shell manufacturing process |
| FR3068271B1 (en) | 2017-06-29 | 2021-12-10 | Safran Aircraft Engines | FOUNDRY PROCESS WITH HOT MOLD CASTING |
| FR3085286B1 (en) | 2018-08-28 | 2021-08-06 | Safran Aircraft Engines | METHOD OF MANUFACTURING A MULTI-LAYER CERAMIC LAYER TEST, TEST OBTAINED BY THE IMPLEMENTATION OF SUCH MANUFACTURING PROCESS AND USE OF SUCH A TEST FOR A UNIAXIAL HOT COMPRESSION TEST |
| CN109261901B (en) * | 2018-11-26 | 2021-01-05 | 惠州市吉邦精密技术有限公司 | Shell manufacturing process of easily collapsible shell |
| FR3103400B1 (en) | 2019-11-21 | 2022-08-19 | Safran Aircraft Engines | FOUNDRY MOLD, METHOD FOR MAKING THE MOLD AND FOUNDRY METHOD |
| FR3145299B1 (en) | 2023-01-27 | 2025-10-24 | Safran Aircraft Engines | Foundry mold |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US3859153A (en) * | 1970-06-25 | 1975-01-07 | Du Pont | Refractory laminate having improved green strength |
| US4363669A (en) * | 1979-12-05 | 1982-12-14 | Merck & Co., Inc. | Dispersible xanthan gum blends |
| DE3602420A1 (en) * | 1986-01-28 | 1987-07-30 | Kempten Elektroschmelz Gmbh | Stable slip casting compound based on finely divided powders containing aluminum nitride |
| GB8911666D0 (en) * | 1989-05-20 | 1989-07-05 | Rolls Royce Plc | Ceramic mould material |
| JPH04224044A (en) * | 1990-12-25 | 1992-08-13 | Hitachi Ltd | Manufacturing method for high-strength molds for precision casting |
| US5407480A (en) * | 1993-09-30 | 1995-04-18 | Vinings Industries, Inc. | Stabilized, high solids, low viscosity smectite slurries, and method of preparation |
| JPH07116773A (en) * | 1993-10-20 | 1995-05-09 | Mitsubishi Heavy Ind Ltd | Production of casting mold for precision casting |
| US5618633A (en) * | 1994-07-12 | 1997-04-08 | Precision Castparts Corporation | Honeycomb casting |
| JPH09155503A (en) * | 1995-12-05 | 1997-06-17 | Hitachi Ltd | Precision casting mold and casting method |
| US5766329A (en) * | 1996-05-13 | 1998-06-16 | Alliedsignal Inc. | Inert calcia facecoats for investment casting of titanium and titanium-aluminide alloys |
| KR100775228B1 (en) * | 1996-09-30 | 2007-11-12 | 히다치 가세고교 가부시끼가이샤 | A Cerium Oxide Particle |
| EP0963262B1 (en) * | 1997-01-27 | 2002-05-02 | AlliedSignal Inc. | Method for producing an integrated crucible and mold for low cost gamma-tial castings |
| US6431255B1 (en) * | 1998-07-21 | 2002-08-13 | General Electric Company | Ceramic shell mold provided with reinforcement, and related processes |
| WO2001045876A1 (en) * | 1999-12-21 | 2001-06-28 | Howmet Research Corporation | Crack resistant shell mold and method |
| JP2001232445A (en) * | 2000-02-23 | 2001-08-28 | Mitsubishi Heavy Ind Ltd | Manufacturing method for mold for single crystal precision casting |
-
2004
- 2004-05-12 FR FR0405145A patent/FR2870148B1/en not_active Expired - Fee Related
-
2005
- 2005-05-10 US US11/125,084 patent/US7370688B2/en not_active Expired - Lifetime
- 2005-05-10 EP EP05103895A patent/EP1595618B1/en not_active Expired - Lifetime
- 2005-05-10 DE DE602005024887T patent/DE602005024887D1/en not_active Expired - Lifetime
- 2005-05-11 CA CA2507171A patent/CA2507171C/en not_active Expired - Lifetime
- 2005-05-11 JP JP2005138393A patent/JP4918227B2/en not_active Expired - Lifetime
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE102016123051A1 (en) * | 2016-11-29 | 2018-05-30 | HÜTTENES-ALBERTUS Chemische Werke Gesellschaft mit beschränkter Haftung | Amino acid-containing molding material mixture for the production of moldings for the foundry industry |
| WO2018099887A1 (en) | 2016-11-29 | 2018-06-07 | HÜTTENES-ALBERTUS Chemische Werke Gesellschaft mit beschränkter Haftung | Amino acid-containing moulding material mixture for production of mouldings for the foundry industry |
Also Published As
| Publication number | Publication date |
|---|---|
| CA2507171C (en) | 2013-07-09 |
| CA2507171A1 (en) | 2005-11-12 |
| JP4918227B2 (en) | 2012-04-18 |
| FR2870148A1 (en) | 2005-11-18 |
| EP1595618A1 (en) | 2005-11-16 |
| US7370688B2 (en) | 2008-05-13 |
| FR2870148B1 (en) | 2006-07-07 |
| DE602005024887D1 (en) | 2011-01-05 |
| JP2005349472A (en) | 2005-12-22 |
| US20050252633A1 (en) | 2005-11-17 |
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