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US3598169A - Method and apparatus for casting directionally solidified discs and the like - Google Patents

Method and apparatus for casting directionally solidified discs and the like Download PDF

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Publication number
US3598169A
US3598169A US807637A US3598169DA US3598169A US 3598169 A US3598169 A US 3598169A US 807637 A US807637 A US 807637A US 3598169D A US3598169D A US 3598169DA US 3598169 A US3598169 A US 3598169A
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US
United States
Prior art keywords
mold
extension
cavity
chill
seed
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.)
Expired - Lifetime
Application number
US807637A
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English (en)
Inventor
Stephen M Copley
Anthony F Giamei
Merton F Hornbecker
Bernard H Kear
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 Aircraft 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 Aircraft Corp filed Critical United Aircraft Corp
Application granted granted Critical
Publication of US3598169A publication Critical patent/US3598169A/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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    • 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
    • B22D27/04—Influencing the temperature of the metal, e.g. by heating or cooling the mould
    • B22D27/045—Directionally solidified castings
    • C—CHEMISTRY; METALLURGY
    • C30—CRYSTAL GROWTH
    • C30B—SINGLE-CRYSTAL GROWTH; UNIDIRECTIONAL SOLIDIFICATION OF EUTECTIC MATERIAL OR UNIDIRECTIONAL DEMIXING OF EUTECTOID MATERIAL; REFINING BY ZONE-MELTING OF MATERIAL; PRODUCTION OF A HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; SINGLE CRYSTALS OR HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; AFTER-TREATMENT OF SINGLE CRYSTALS OR A HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; APPARATUS THEREFOR
    • C30B11/00—Single-crystal growth by normal freezing or freezing under temperature gradient, e.g. Bridgman-Stockbarger method
    • C—CHEMISTRY; METALLURGY
    • C30—CRYSTAL GROWTH
    • C30B—SINGLE-CRYSTAL GROWTH; UNIDIRECTIONAL SOLIDIFICATION OF EUTECTIC MATERIAL OR UNIDIRECTIONAL DEMIXING OF EUTECTOID MATERIAL; REFINING BY ZONE-MELTING OF MATERIAL; PRODUCTION OF A HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; SINGLE CRYSTALS OR HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; AFTER-TREATMENT OF SINGLE CRYSTALS OR A HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; APPARATUS THEREFOR
    • C30B29/00—Single crystals or homogeneous polycrystalline material with defined structure characterised by the material or by their shape
    • C30B29/10—Inorganic compounds or compositions
    • C30B29/52—Alloys

Definitions

  • 3,260,505 to VerSnyder describes the casting'of directionally solidified parts with a particular orientation of the crystalline growth with respect to the longitudinal axis of the part.
  • FIG. 1 is a vertical sectional view paratus embodying the invention.
  • FIG. 2 is a fragmentary sectional view similar to a portion of partially schematic of ap FIG. 1 showinga modification.
  • FIG. 3 is a schematic view showing the dendritic orientation.
  • FIG. 4 is a vertical sectionalview ofa complete turbine disc including blades.
  • FIG. 5 is a fragmentary sectional view along line 5-5 of FIG.
  • FIG. 6 is a view similar to FIG. 1 ofanother modification.
  • FIG. 7 is a horizontal sectional view of the modification of FIG. 6.
  • FIG. 8' is a vertical sectional view similar to FIG. 6 of another modification.
  • FIG. 9 is a fragmentary horizontal view through the mold of FIG. 8.
  • the apparatus includes a chill plate 10 supporting a mold 12, the latter having a relatively large horizontal dimension, and shown as a mold for producing a disc. Atone side of the mold an axial projection 14 extends downwardly to engage the chill plate, and an upwardly extending axial projection 16 provides a filling opening for the mold.
  • the mold is shown as a split-shell mold, being in two parts 120 and 12b although a single piece shell mold may be utilized.- The mold may be enclosed in part by insulation 18 around the axial extension 14 and the disc forming portion is covered 1 from the periphery inwardly by insulation 20 that decreases in thickness toward the center of the disc.
  • Annular heating coils 22 and 24 are positioned above and below the mold adjacent to the axial projections. and other heating coils 26 and 28 are periphery and concentric to the coils 22 and 24.
  • a heating coil 30 surrounds the periphery of the mold, as shown.
  • the mold is positioned within a heating chamber, not shown, to raise the temperature of the entire mold above the melting point of the alloy to be poured and, when adequate heating is accomplished, the molten alloy, su-
  • the radial thermal gradient thus produced causes radial growth of the dendrites in the peripheral vertical columnar grains extending upwardly from the axial portion 14 and the radial competition between the several orientations of dendrites in the several rains will result in the radially oriented grains growing the fastest and producing substantially radially arranged dendrites in the entire disc.
  • the radial thermal gradient produces the radial growth within the disc in the same way that the vertically oriented grains outgrow the other grains in the axial portion 14. This effect is described in the US. Pat. No. 3,260,505 to VerSnyder. Grain growth occuring in this manner produces an radial orientation and tangential orientation.
  • the axially extending portion 14' ofa mold 12' which is otherwise arranged as in FIG. 1 has a seed 36 therein resting on the chill plate.
  • This seed is made up of wedges 38 each having the desired orientation for the portion of the disc extending outwardly therefrom.
  • the seed wedges cause vertical dendritic growth with each of the several seed wedges providing the desired horizontal orientation for the adjacent portion of the cast disc.
  • FIG. 3 The resulting orientation is shown in FIG. 3 where the seed 36 is made up of wedges, for example, as shown, theseed is made up of eight wedges each of 45 and each having the orientation indicated.
  • the result is a disc made up of interacting dendritic growths producing approximately a radial and a tangential orientation. Use of many more wedge elements will disc.
  • the controlled radial thermal gradient provided by the structure of FIG. 1 permits controlled grain growth through the entire disc to its periphery.
  • FIGS. 4 and 5 One particular article that may prove particularly useful in a casting of this character is representedby FIGS. 4 and 5.
  • a mold 40 defining a disc-shaped cavity 42, and having the downwardly extending axial projection 44 corresponding to the extension 14 of FIG. 1.
  • Projecting outwardly from the periphery of the mold 40 are blade formingprojeccavities 48 communicating above described.
  • the disc and blades for a turbine disc may all be cast in a single piece with the preferred orientation of the grain growth in the disc and with the desired radial orientation in the blades for the desired strength characteristics.
  • the number of seed wedges would be selected to insure the precise radial grain growth in the blades.
  • the seed used would have possibly one wedge for each two blades, the-orientation of the several wedges being carefully selected for precise radial grain growth.
  • FIGS. 6 and 7 Another alternative is shown in FIGS. 6 and 7 where the mold is made up of individual mold elements 50 extending precisely radial grain'distribution within the v radially outward from a central casting cavity 52 surrounding a vertical cylindrical chill 54.
  • the chill 54 is surrounded by seed segments 56, one for each mold element 50 and these segments establish the direction of the grain growth in each mold.
  • the grain growth proceeds radially outward in each mold 50 and its connecting mold passage 58, with the temperature gradient in a radial direction controlled by the central chill and the use of annular heating coils as in FIG. 1.
  • This controlled thermal gradient which will produce directionally solidified alloy in each mold element 50 with the direction of the grains radial in each cast article, is described in U.S. Pat. No. 3,260,505 to VerSnyder above referred to.
  • the cast articles are represented as turbine blades and would be cast from the type of high temperature alloy of which several examples are given in the VerSnyder patent.
  • FIG. 8 An alternate proposed method of producing discs, with or without integral blades, is shown in FIG. 8 in which the mold 60 has an annular disc cavity 62 and surrounds a central vertical cylindrical chill 64.
  • the periphery of the mold may have recesses 66 therein for forming the individual blades on the periphery of the disc when the cast article is intended as a bladed turbine disc.
  • a ring 68 of individual seed segments 70, each of directionally solidified material with properly oriented grains surrounds the chill at the disc level to control the directional orientation of the grain growth in the disc.
  • annular heat control coils similar to those in FIG. 1 are used here to produce the desired radial thermal gradient. By using the appropriate number of seed segments the precise radial grain growth desired may be obtained throughout the disc and into the individual blades.
  • Apparatus for casting relatively flat articles with a selected grain orientation including a chill plate, a mold hav' ing an article-shaped cavity and a centrally located downward extension forming a vertically positioned cavity communicating with said first cavity and opening onto the chill plate, and a plurality of heating means adjacent to the mold and arranged on top and bottom of the article cavity and in steps outwardly from the downward extension to the remote edge of the mold to establish a thermal gradient radially outward from the extension toward the remote edge ofthe mold.
  • Apparatus as in claim I in which a seed having multiple orientations is placed on the chill plate and within the extension.
  • the method of casting discs and the like including the step of providing a mold having an article forming cavity and a downward extension thereon forming a vertical cavity communicating with said first cavity and open at the bottom, providing a chill plate on which the downward extension rests, heating the mold to a point above the melting point of the al loy, pouring the alloy into the mold, cooling the chill plate to remove heat from the alloy, and cooling the mold in steps radially outward from the extension thereby providing a radially outward thermal gradient from the downward extension of the mold to the outer periphery of the mold laterally remote therefrom.
  • the extension is located centrally of the cavity, and the step of cooling the mold in steps radially outward produces a radial thermal gradient horizontally from the central extension to the periphery of the annulus thereby promoting a radial grain growth horizontally in the mold.
  • Apparatus for casting relatively flat articles with a selected grain orientation including a chill, a mold defining a ring-shaped cavity, one surface of which is defined by the chill, and a plurality of annular heating means adjacent to the mold and arranged in steps radially outward outwardly from the axis of the ring and on opposite sides thereof to establish a thermal gradient from the axis to the periphery of the mold.
  • Apparatus as in claim 11 in which the chill is a cylinder extending axially of and surrounded by the mold.
  • Apparatus as in claim 11 in which the cavity defines a plurality of radially extending article forming cavities all communicating with a central cavity in contact with the chill.
  • Apparatus as in claim 11 in which the chill is a vertically extending centrally located chill surrounded by the mold, and in which a seed made up of properly oriented segments surrounds the chill within the cavity.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Crystallography & Structural Chemistry (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Inorganic Chemistry (AREA)
  • Mechanical Engineering (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
US807637A 1969-03-13 1969-03-13 Method and apparatus for casting directionally solidified discs and the like Expired - Lifetime US3598169A (en)

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Application Number Priority Date Filing Date Title
US80763769A 1969-03-13 1969-03-13

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Country Status (7)

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US (1) US3598169A (de)
JP (1) JPS4815134B1 (de)
CA (1) CA926737A (de)
DE (1) DE2010570B2 (de)
FR (1) FR2041073B1 (de)
GB (1) GB1264053A (de)
SE (1) SE348960B (de)

Cited By (24)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE2242111A1 (de) * 1971-09-15 1973-03-22 United Aircraft Corp Verfahren und vorrichtung zum giessen von gegenstaenden mit gerichtet erstarrtem gefuege
US3729050A (en) * 1971-08-10 1973-04-24 Howmet Corp Refractory support for shell molds
US3858641A (en) * 1971-02-12 1975-01-07 Minnesota Mining & Mfg Metal casting in thin walled molds
US4016829A (en) * 1973-02-26 1977-04-12 Hitachi, Ltd. Apparatus for crystal growth
US4096025A (en) * 1974-02-21 1978-06-20 The United States Of America As Represented By The Secretary Of The Army Method of orienting seed crystals in a melt, and product obtained thereby
DE2949446A1 (de) * 1978-12-13 1980-06-26 United Technologies Corp Verfahren und form fuer epitaxiale erstarrung
US4213497A (en) * 1978-08-21 1980-07-22 General Electric Company Method for casting directionally solidified articles
US4240495A (en) * 1978-04-17 1980-12-23 General Motors Corporation Method of making cast metal turbine wheel with integral radial columnar grain blades and equiaxed grain disc
US4289570A (en) * 1978-12-13 1981-09-15 United Technologies Corporation Seed and method for epitaxial solidification
EP0066971A3 (de) * 1981-06-08 1983-03-16 Trw Inc. Verfahren zum Giessen eines Gegenstandes
US4469160A (en) * 1981-12-23 1984-09-04 United Technologies Corporation Single crystal solidification using multiple seeds
US4499155A (en) * 1983-07-25 1985-02-12 United Technologies Corporation Article made from sheet having a controlled crystallographic orientation
US4605452A (en) * 1981-12-14 1986-08-12 United Technologies Corporation Single crystal articles having controlled secondary crystallographic orientation
US4659288A (en) * 1984-12-10 1987-04-21 The Garrett Corporation Dual alloy radial turbine rotor with hub material exposed in saddle regions of blade ring
US4804311A (en) * 1981-12-14 1989-02-14 United Technologies Corporation Transverse directional solidification of metal single crystal articles
US4813470A (en) * 1987-11-05 1989-03-21 Allied-Signal Inc. Casting turbine components with integral airfoils
US4850419A (en) * 1982-09-01 1989-07-25 Trw Inc. Method of casting a one-piece wheel
US5061154A (en) * 1989-12-11 1991-10-29 Allied-Signal Inc. Radial turbine rotor with improved saddle life
US5292385A (en) * 1991-12-18 1994-03-08 Alliedsignal Inc. Turbine rotor having improved rim durability
FR2734188A1 (fr) * 1982-09-28 1996-11-22 Snecma Procede de fabrication de pieces monocristallines
US5611389A (en) * 1980-12-30 1997-03-18 Societe Nationale D'etude Et De Construction De Moterus D'aviation S.N.E.C.M.A. Procedure for the fabrication of crystalline blades
US5730582A (en) * 1997-01-15 1998-03-24 Essex Turbine Ltd. Impeller for radial flow devices
US20100206510A1 (en) * 2008-06-24 2010-08-19 Garlock Robert M Method and apparatus for casting metal articles
FR3141083A1 (fr) * 2022-10-21 2024-04-26 Safran Procédé de fabrication par moulage d’un disque aubagé monobloc

Families Citing this family (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4074340A (en) * 1976-10-18 1978-02-14 Vitramon, Incorporated Trimmable monolithic capacitors
JPS56110645U (de) * 1980-01-25 1981-08-27
JPS593621U (ja) * 1982-06-29 1984-01-11 株式会社村田製作所 チツプ型圧電振動部品
JPS60123122A (ja) * 1983-12-07 1985-07-01 Murata Mfg Co Ltd チップ型圧電共振部品とその製造方法
AT387167B (de) * 1986-08-11 1988-12-12 Vaillant Gmbh Verfahren zum vorheizen einer druckgiessform
EP0506608B1 (de) * 1991-03-26 1996-12-27 Sulzer Innotec Ag Vorrichtung zur Herstellung von gerichtet erstarrten Gussstücken
EP1284310A1 (de) * 2001-08-13 2003-02-19 Siemens Aktiengesellschaft Verfahren zur Herstellung eines einkristallinen Bauteils komplexer Formstruktur
JP5754636B2 (ja) * 2011-08-04 2015-07-29 株式会社不二越 ゲルマニウムの溶融成形方法及び装置
JP5861928B2 (ja) * 2012-01-30 2016-02-16 株式会社不二越 ゲルマニウムの溶融成形方法

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2791813A (en) * 1954-10-28 1957-05-14 James K Delano Apparatus and method for growing crystals having a controlled internal junction structure
US3373795A (en) * 1965-08-10 1968-03-19 Trw Inc Gating of unshrouded airfoils to permit directional solidification
US3405220A (en) * 1965-07-16 1968-10-08 United Aircraft Corp Induction electric mold heater
US3515205A (en) * 1968-03-20 1970-06-02 United Aircraft Corp Mold construction forming single crystal pieces

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2791813A (en) * 1954-10-28 1957-05-14 James K Delano Apparatus and method for growing crystals having a controlled internal junction structure
US3405220A (en) * 1965-07-16 1968-10-08 United Aircraft Corp Induction electric mold heater
US3373795A (en) * 1965-08-10 1968-03-19 Trw Inc Gating of unshrouded airfoils to permit directional solidification
US3515205A (en) * 1968-03-20 1970-06-02 United Aircraft Corp Mold construction forming single crystal pieces

Cited By (25)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3858641A (en) * 1971-02-12 1975-01-07 Minnesota Mining & Mfg Metal casting in thin walled molds
US3729050A (en) * 1971-08-10 1973-04-24 Howmet Corp Refractory support for shell molds
DE2242111A1 (de) * 1971-09-15 1973-03-22 United Aircraft Corp Verfahren und vorrichtung zum giessen von gegenstaenden mit gerichtet erstarrtem gefuege
US4016829A (en) * 1973-02-26 1977-04-12 Hitachi, Ltd. Apparatus for crystal growth
US4096025A (en) * 1974-02-21 1978-06-20 The United States Of America As Represented By The Secretary Of The Army Method of orienting seed crystals in a melt, and product obtained thereby
US4240495A (en) * 1978-04-17 1980-12-23 General Motors Corporation Method of making cast metal turbine wheel with integral radial columnar grain blades and equiaxed grain disc
US4213497A (en) * 1978-08-21 1980-07-22 General Electric Company Method for casting directionally solidified articles
DE2949446A1 (de) * 1978-12-13 1980-06-26 United Technologies Corp Verfahren und form fuer epitaxiale erstarrung
US4289570A (en) * 1978-12-13 1981-09-15 United Technologies Corporation Seed and method for epitaxial solidification
US5611389A (en) * 1980-12-30 1997-03-18 Societe Nationale D'etude Et De Construction De Moterus D'aviation S.N.E.C.M.A. Procedure for the fabrication of crystalline blades
EP0066971A3 (de) * 1981-06-08 1983-03-16 Trw Inc. Verfahren zum Giessen eines Gegenstandes
US4605452A (en) * 1981-12-14 1986-08-12 United Technologies Corporation Single crystal articles having controlled secondary crystallographic orientation
US4804311A (en) * 1981-12-14 1989-02-14 United Technologies Corporation Transverse directional solidification of metal single crystal articles
US4469160A (en) * 1981-12-23 1984-09-04 United Technologies Corporation Single crystal solidification using multiple seeds
US4850419A (en) * 1982-09-01 1989-07-25 Trw Inc. Method of casting a one-piece wheel
FR2734188A1 (fr) * 1982-09-28 1996-11-22 Snecma Procede de fabrication de pieces monocristallines
US4499155A (en) * 1983-07-25 1985-02-12 United Technologies Corporation Article made from sheet having a controlled crystallographic orientation
US4659288A (en) * 1984-12-10 1987-04-21 The Garrett Corporation Dual alloy radial turbine rotor with hub material exposed in saddle regions of blade ring
US4813470A (en) * 1987-11-05 1989-03-21 Allied-Signal Inc. Casting turbine components with integral airfoils
US5061154A (en) * 1989-12-11 1991-10-29 Allied-Signal Inc. Radial turbine rotor with improved saddle life
US5292385A (en) * 1991-12-18 1994-03-08 Alliedsignal Inc. Turbine rotor having improved rim durability
US5730582A (en) * 1997-01-15 1998-03-24 Essex Turbine Ltd. Impeller for radial flow devices
US20100206510A1 (en) * 2008-06-24 2010-08-19 Garlock Robert M Method and apparatus for casting metal articles
US7958928B2 (en) 2008-06-24 2011-06-14 Pcc Airfoils, Inc. Method and apparatus for casting metal articles
FR3141083A1 (fr) * 2022-10-21 2024-04-26 Safran Procédé de fabrication par moulage d’un disque aubagé monobloc

Also Published As

Publication number Publication date
DE2010570B2 (de) 1972-05-10
FR2041073B1 (de) 1974-05-03
GB1264053A (en) 1972-02-16
JPS4815134B1 (de) 1973-05-12
FR2041073A1 (de) 1971-01-29
SE348960B (de) 1972-09-18
CA926737A (en) 1973-05-22
DE2010570A1 (de) 1970-09-24

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