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US20050241797A1 - Method for producing a hollow cast component having an inner coating - Google Patents

Method for producing a hollow cast component having an inner coating Download PDF

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Publication number
US20050241797A1
US20050241797A1 US11/117,195 US11719505A US2005241797A1 US 20050241797 A1 US20050241797 A1 US 20050241797A1 US 11719505 A US11719505 A US 11719505A US 2005241797 A1 US2005241797 A1 US 2005241797A1
Authority
US
United States
Prior art keywords
component
coating
cavity
cast
mold insert
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.)
Abandoned
Application number
US11/117,195
Other languages
English (en)
Inventor
Knut Halberstadt
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.)
Siemens AG
Original Assignee
Siemens AG
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 Siemens AG filed Critical Siemens AG
Assigned to SIEMENS AKTIENGESELLSCHAFT reassignment SIEMENS AKTIENGESELLSCHAFT ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: HALBERSTADT, KNUT
Publication of US20050241797A1 publication Critical patent/US20050241797A1/en
Abandoned legal-status Critical Current

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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
    • F01D5/12—Blades
    • F01D5/14—Form or construction
    • F01D5/18—Hollow blades, i.e. blades with cooling or heating channels or cavities; Heating, heat-insulating or cooling means on blades
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C1/00—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds
    • B22C1/16—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by the use of binding agents; Mixtures of binding agents
    • B22C1/165—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by the use of binding agents; Mixtures of binding agents in the manufacture of multilayered shell moulds
    • 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
    • B22C9/12—Treating moulds or cores, e.g. drying, hardening
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D27/00—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting
    • B22D27/15—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting by using vacuum
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D29/00—Removing castings from moulds, not restricted to casting processes covered by a single main group; Removing cores; Handling ingots
    • B22D29/001—Removing cores
    • B22D29/002—Removing cores by leaching, washing or dissolving
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
    • F01D5/12—Blades
    • F01D5/28—Selecting particular materials; Particular measures relating thereto; Measures against erosion or corrosion
    • F01D5/288—Protective coatings for blades
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05B—INDEXING SCHEME RELATING TO WIND, SPRING, WEIGHT, INERTIA OR LIKE MOTORS, TO MACHINES OR ENGINES FOR LIQUIDS COVERED BY SUBCLASSES F03B, F03D AND F03G
    • F05B2230/00—Manufacture
    • F05B2230/90—Coating; Surface treatment
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2230/00—Manufacture
    • F05D2230/90—Coating; Surface treatment

Definitions

  • the present invention relates to a method for producing a hollow cast component, in particular a hollow cast turbine blade, having an inner coating on the walls of at least one cavity.
  • MCrAlY coatings are suitable as protection against oxidation and/or corrosion in this context.
  • an MCrAlY coating should be understood as a coating of a metal alloy which comprises chromium (Cr) and aluminum (Al), and in which Y stands for yttrium or a rare earth element and M stands for iron (Fe), cobalt (Co) or nickel (Ni).
  • the inner walls of hollow cast components operated in a strongly heating environment may also be exposed to temperatures which necessitate protection of the inner walls against oxidation and/or corrosion, so that the component can actually achieve the intended service life.
  • Turbine components are examples of such hollow cast components subject to strong heating. During operation, turbine blades are exposed to high temperatures and generally have cavities through which the coolant is fed. Under certain operating conditions, temperatures that necessitate protection of the inner walls against oxidation and/or corrosion may occur in these cavities.
  • the first object is achieved by a method as claimed in the claims, and the second object is achieved by a hollow cast turbine component as claimed in the claims.
  • the component is cast from a base material.
  • a casting mold which comprises at least one mold insert for defining at least one cavity is used for the casting.
  • the coating material for the inner coating of the component is applied to at least one mold insert before the component is cast. The mold insert is then removed from the cavity after the casting.
  • the inner coating is produced first and then the component is cast around it.
  • an inner coating in particular with an MCrAlY inner coating.
  • the material of the mold insert is in this case selected so that it can be removed from the cavity of the component once it is finished, without taking the coating material with it.
  • those materials which can be removed from the cavity by means of a chemical method which does not attack the coating material and the base material of the component are suitable as the material for the mold insert.
  • ceramic mold inserts which can be removed from cavities of turbine components by means of a suitable lye, which does not attack an MCrAlY coating or the base material of turbine components. Ceramic materials, in particular, are therefore suitable as materials for mold inserts to cast turbine components, for instance turbine blades.
  • the casting temperature when casting the component is particularly selected so that it is lower than the melting temperature of the coating material, so as to avoid melting the coating material during the casting process and therefore mixing with the base material of the component.
  • the application of the coating material to the mold insert may, for example, be carried out by means of high-energy spray methods (high-velocity oxygen fuel spraying, abbreviated to HVOF) or plasma spraying (abbreviated to APS).
  • high-energy spray methods high-velocity oxygen fuel spraying, abbreviated to HVOF
  • plasma spraying abbreviated to APS
  • a hollow cast turbine blade according to the invention has at least one cavity and an inner coating present in the cavity, in particular an MCrAlY coating.
  • FIG. 1 shows a hollow cast turbine component in a schematic representation.
  • FIGS. 2-7 show various stages in the production of the hollow cast turbine blade as a highly schematized representation.
  • FIG. 1 schematically represents a hollow cast turbine blade 1 in a sectional view.
  • the turbine blade 1 comprises a blade body 2 in which, in the present exemplary embodiment, four cavities 3 , 5 , 7 , 9 are formed which, for example, are used to feed cooling air through.
  • the blade body 2 has an outer surface 12 , which is provided with an MCrAlY coating for protection against oxidation and/or corrosion.
  • the blade body 2 also has inner surfaces 4 , 6 , 8 , 10 which bound the cavities 3 , 5 , 7 , 9 and form the inner walls of the cavities.
  • the inner surfaces 4 , 6 , 8 , 10 are likewise provided with an MCrAlY coating 14 , 16 , 18 , 20 in order to protect them too against oxidation and/or corrosion.
  • the method for producing the turbine blade 1 described with reference to FIG. I will be explained below with reference to FIGS. 2 to 7 .
  • the method may, however, also be employed for the inner coatings of other hollow cast components.
  • a ceramic mold insert 22 for the casting mold to produce the turbine blade is formed and sintered ( FIG. 2 ).
  • an MCrAlY coating 14 is applied to the ceramic mold insert 22 .
  • a high-energy spray method such as high-velocity oxygen fuel spraying (HVOF) or plasma spraying (APS) may be used for this purpose.
  • HVOF high-velocity oxygen fuel spraying
  • APS plasma spraying
  • the thickness with which the MCrAlY coating 14 is applied to the mold insert depends on the thickness with which the inner walls of the turbine blade are intended to be coated.
  • a wax model 24 of the turbine blade is injected onto the mold insert 22 ( FIG. 4 ).
  • the outer mold half 26 of the mold is then applied to the wax model 24 .
  • the wax is then burnt off and the mold half 26 is sintered in order to make the casting mold 28 ( FIG. 5 ).
  • the turbine blade 1 is cast in a vacuum.
  • the casting of the turbine blade typically takes place at casting temperatures of less than 1500° C.
  • the melting point of the MCrAlY coating 14 is typically more than 1600° C. Melting of the coating 14 during the casting process, and therefore mixing of the coating material with the base material of the turbine blade 1 , do not therefore take place.
  • the casting temperatures must also be lower than the melting temperature of the coating material, if melting of the coating and mixing with the base material are intended to be avoided.
  • the mold half 26 is removed and the blade 1 is cleaned ( FIG. 6 ).
  • the mold insert 22 is leached, i.e. the ceramic mold insert 22 is removed from the solidified turbine blade 1 by means of a lye. Since the MCrAlY coating 14 as well as the blade material are resistant to the lyes being used, the MCrAlY coating 14 remains on the inside of the turbine blade I when the ceramic mold insert 22 is leached ( FIG. 7 ). The turbine blade produced in this way can then be mechanically processed in the conventional way and coated on the outside.
  • the described method is suitable not only for inner coatings of turbine blades but, in principle, also for inner coatings of other hollow cast components. It is likewise possible to use the method to apply coatings other than MCrAlY coatings.
  • the mold insert need not necessarily be made of a ceramic material. It is merely necessary to ensure that the mold insert can be removed without taking with it the coating applied to the inside of the workpiece.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Turbine Rotor Nozzle Sealing (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
US11/117,195 2004-05-03 2005-04-28 Method for producing a hollow cast component having an inner coating Abandoned US20050241797A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
EP04010492.9 2004-05-03
EP04010492A EP1593445B1 (de) 2004-05-03 2004-05-03 Verfahren zum Herstellen eines hohlgegossenen Bauteils mit Innenbeschichtung

Publications (1)

Publication Number Publication Date
US20050241797A1 true US20050241797A1 (en) 2005-11-03

Family

ID=34924837

Family Applications (1)

Application Number Title Priority Date Filing Date
US11/117,195 Abandoned US20050241797A1 (en) 2004-05-03 2005-04-28 Method for producing a hollow cast component having an inner coating

Country Status (4)

Country Link
US (1) US20050241797A1 (zh)
EP (1) EP1593445B1 (zh)
CN (1) CN1318160C (zh)
DE (1) DE502004004360D1 (zh)

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20110171394A1 (en) * 2008-08-26 2011-07-14 Allen David B Method of making a combustion turbine component using thermally sprayed transient liquid phase forming layer
US20110256321A1 (en) * 2007-11-28 2011-10-20 Reynolds George H Article having composite layer
US20140183782A1 (en) * 2013-01-03 2014-07-03 General Electric Company Mold assembly for forming a cast component and method of manufacturing a mold assembly
US20150183026A1 (en) * 2013-12-27 2015-07-02 United Technologies Corporation Investment mold having metallic donor element
CN104812994A (zh) * 2012-11-13 2015-07-29 西门子能量股份有限公司 形成具有在叶尖附近带薄壁部分的主壁的长燃气轮机轮叶的方法
US9975173B2 (en) 2013-06-03 2018-05-22 United Technologies Corporation Castings and manufacture methods
US20230304409A1 (en) * 2020-08-06 2023-09-28 Safran Protection against oxidation or corrosion of a hollow part made of a superalloy

Families Citing this family (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2329901A1 (de) * 2009-12-03 2011-06-08 Siemens Aktiengesellschaft Gussform mit stabilisiertem inneren Gusskern, Gussverfahren und Gussteil
CN102581217A (zh) * 2012-02-20 2012-07-18 含山县全兴内燃机配件有限公司 一种用于内燃机工作内腔的复合铸渗层的制备方法
FR3071867B1 (fr) * 2017-10-02 2020-07-31 Safran Aircraft Engines Aube composite a matrice ceramique et procede de fabrication d'une telle aube
US20200164431A1 (en) * 2018-11-28 2020-05-28 GM Global Technology Operations LLC Methods for manufacturing cast components with integral thermal barrier coatings

Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4332843A (en) * 1981-03-23 1982-06-01 General Electric Company Metallic internal coating method
US4532974A (en) * 1981-07-03 1985-08-06 Rolls-Royce Limited Component casting
US4548256A (en) * 1982-11-03 1985-10-22 The Secretary Of State For Defence In Her Britannic Majesty's Government Of The United Kingdom Of Great Britain And Northern Ireland Casting of metal articles
US5215785A (en) * 1990-11-10 1993-06-01 Mtu Motoren- Und Turbinen- Union Muenchen Gmbh Method for the powder pack coating of hollow bodies
US5915452A (en) * 1995-06-07 1999-06-29 Howmet Research Corporation Apparatus for removing cores from castings
US6029736A (en) * 1997-08-29 2000-02-29 Howmet Research Corporation Reinforced quartz cores for directional solidification casting processes
US7055574B2 (en) * 2004-07-27 2006-06-06 Honeywell International Inc. Method of producing metal article having internal passage coated with a ceramic coating

Family Cites Families (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
SK23293A3 (en) * 1990-09-25 1993-07-07 Allied Signal Inc Production of complex cavities inside castings or semi solid forms
DE19856901C2 (de) * 1998-12-10 2003-01-16 Mtu Aero Engines Gmbh Verfahren zum Beschichten von Hohlkörpern

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4332843A (en) * 1981-03-23 1982-06-01 General Electric Company Metallic internal coating method
US4532974A (en) * 1981-07-03 1985-08-06 Rolls-Royce Limited Component casting
US4548256A (en) * 1982-11-03 1985-10-22 The Secretary Of State For Defence In Her Britannic Majesty's Government Of The United Kingdom Of Great Britain And Northern Ireland Casting of metal articles
US5215785A (en) * 1990-11-10 1993-06-01 Mtu Motoren- Und Turbinen- Union Muenchen Gmbh Method for the powder pack coating of hollow bodies
US5915452A (en) * 1995-06-07 1999-06-29 Howmet Research Corporation Apparatus for removing cores from castings
US6029736A (en) * 1997-08-29 2000-02-29 Howmet Research Corporation Reinforced quartz cores for directional solidification casting processes
US7055574B2 (en) * 2004-07-27 2006-06-06 Honeywell International Inc. Method of producing metal article having internal passage coated with a ceramic coating

Cited By (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20110256321A1 (en) * 2007-11-28 2011-10-20 Reynolds George H Article having composite layer
US20110171394A1 (en) * 2008-08-26 2011-07-14 Allen David B Method of making a combustion turbine component using thermally sprayed transient liquid phase forming layer
CN104812994A (zh) * 2012-11-13 2015-07-29 西门子能量股份有限公司 形成具有在叶尖附近带薄壁部分的主壁的长燃气轮机轮叶的方法
US20140183782A1 (en) * 2013-01-03 2014-07-03 General Electric Company Mold assembly for forming a cast component and method of manufacturing a mold assembly
US9975173B2 (en) 2013-06-03 2018-05-22 United Technologies Corporation Castings and manufacture methods
US11213885B2 (en) 2013-06-03 2022-01-04 Raytheon Technologies Corporation Castings and manufacture methods
US12042854B2 (en) 2013-06-03 2024-07-23 Rtx Corporation Castings and manufacture methods
US20150183026A1 (en) * 2013-12-27 2015-07-02 United Technologies Corporation Investment mold having metallic donor element
US20230304409A1 (en) * 2020-08-06 2023-09-28 Safran Protection against oxidation or corrosion of a hollow part made of a superalloy
US12454891B2 (en) * 2020-08-06 2025-10-28 Safran Protection against oxidation or corrosion of a hollow part made of a superalloy

Also Published As

Publication number Publication date
DE502004004360D1 (de) 2007-08-30
EP1593445B1 (de) 2007-07-18
CN1318160C (zh) 2007-05-30
CN1693006A (zh) 2005-11-09
EP1593445A1 (de) 2005-11-09

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Legal Events

Date Code Title Description
AS Assignment

Owner name: SIEMENS AKTIENGESELLSCHAFT, GERMANY

Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:HALBERSTADT, KNUT;REEL/FRAME:016524/0622

Effective date: 20050321

STCB Information on status: application discontinuation

Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION