U.S. patent number 3,598,169 [Application Number 04/807,637] was granted by the patent office on 1971-08-10 for method and apparatus for casting directionally solidified discs and the like.
This patent grant is currently assigned to United Aircraft Corporation. Invention is credited to Stephen M. Copley, Anthony F. Giamei, Merton F. Hornbecker, Bernard H. Kear.
United States Patent |
3,598,169 |
Copley , et al. |
August 10, 1971 |
METHOD AND APPARATUS FOR CASTING DIRECTIONALLY SOLIDIFIED DISCS AND
THE LIKE
Abstract
Apparatus and method for inducing radial directional
solidification in parts having a relatively large dimension at
right angles to the major axis such as discs and the like, in
which, for example, a [010] radial and [100] tangential orientation
is generated.
Inventors: |
Copley; Stephen M. (Madison,
CT), Giamei; Anthony F. (Middletown, CT), Hornbecker;
Merton F. (Woodbury, CT), Kear; Bernard H. (Madison,
CT) |
Assignee: |
United Aircraft Corporation
(East Hartford, CT)
|
Family
ID: |
25196848 |
Appl.
No.: |
04/807,637 |
Filed: |
March 13, 1969 |
Current U.S.
Class: |
164/122.1;
164/353; 416/241R; 117/939; 164/125; 164/361; 416/244A |
Current CPC
Class: |
C30B
11/00 (20130101); C30B 29/52 (20130101); B22D
27/045 (20130101); C30B 11/00 (20130101); C30B
29/52 (20130101) |
Current International
Class: |
C30B
11/00 (20060101); B22D 27/04 (20060101); B22d
025/06 () |
Field of
Search: |
;164/60,122,125,127,338,353,361 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Overholser; J. Spencer
Assistant Examiner: Roethel; John E.
Claims
We claim:
1. Apparatus for casting relatively flat articles with a selected
grain orientation including a chill plate, a mold having 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
of the mold.
2. Apparatus as in claim 1 in which the heating means are arranged
in concentric rings from the extension to the periphery of the
mold.
3. Apparatus as in claim 2 in which insulation is placed on the
mold from the extension to the periphery in gradually decreasing
thickness from the periphery toward the extension.
4. Apparatus as in claim 1 in which a selectively oriented seed is
placed on the chill plate and within the extension.
5. Apparatus as in claim 1 in which a seed having multiple
orientations is placed on the chill plate and within the
extension.
6. 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 alloy, 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.
7. In the method of claim 6 in which the mold cavity is relatively
flat, 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.
8. In the method of claim 6 the step of providing a seed in the
extension before pouring the alloy with the orientation of the
grain of the seed in the desired orientation for the solidified
alloy in the cast article.
9. In the method of claim 7 the added step of providing a suitably
oriented seed in the extension before pouring the alloy.
10. In the method of claim 7 the added step of providing a seed
made up of wedges each of radially oriented grains to produce an
annulus in which the grains are substantially all radially
oriented.
11. 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.
12. Apparatus as in claim 11 in which the chill is a cylinder
extending axially of and surrounded by the mold.
13. 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.
14. 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.
Description
BACKGROUND OF THE INVENTION
The U.S. Pat. No. 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. In casting large diameter parts it is desirable to control
the orientation of the dendritic growth in order to control the
strength characteristics. In casting large diameter parts it is
desirable to control the solidification to produce the desired
crystalline orientation throughout the disc in order to obtain the
desired strength or other characteristics in the desired direction
within the disc.
SUMMARY OF INVENTION
One feature of the invention is an arrangement by which to cast a
relatively flat directionally solidified article in which the
dendritic growth has the selected orientation therein. Another
feature is a method by which to produce such a cast article. One
feature of the invention is the production of directionally
solidified cast articles having substantially a 8 100] tangential
orientation.
One particular feature is a method and apparatus for producing
discs adapted to be loaded in a radial direction, for example,
turbine discs in which the dendritic orientation is substantially
in a radial direction and in a tangential direction.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a vertical sectional view partially schematic of
apparatus embodying the invention.
FIG. 2 is a fragmentary sectional view similar to a portion of FIG.
1 showing a modification.
FIG. 3 is a schematic view showing the dendritic orientation.
FIG. 4 is a vertical sectional view of a mold for producing a
complete turbine disc including blades.
FIG. 5 is a fragmentary sectional view along line 5-5 of FIG.
4.
FIG. 6 is a view similar to FIG. 1 of another 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.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, 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. At
one 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 12a 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 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 located above and below the mold nearer to the periphery and
concentric to the coils 22 and 24. A heating coil 30 surrounds the
periphery of the mold, as shown.
In operation, the technique described in U.S. Pat. No. 3,260,505 to
VerSnyder is followed to obtain a directionally solidified casting.
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, superheated to at least 100.degree. above the
melting point is poured into the mold through a sprue 32, and
coolant is supplied to the chill plate to establish a steep
temperature gradient within the mold. This causes the formation of
vertically oriented directionally solidified grains in the axial
projection 14 and solidification proceeds upwardly.
While this is occuring heat has been supplied to the mold by the
heating coils thereby maintaining the portion of the mold
peripherally out from the axial projections and the metal thereon
above the melting point. As solidification begins to take place
into the portion of the mold directly above the axial portion 14
the grain growth continues vertically by reason of the heat loss to
the chill plate and the vertical grains on the periphery of the
solidifying portion begin to grow radially outward. When the
solidification reaches a position represented by the dotted line
34, a radial thermal gradient is produced in the disc portion of
the mold by gradually reducing the heating effect from the axis
outwardly toward the periphery of the disc. Thus the power to coils
22 and 24 is reduced first then the power to coils 26 and 28, and
finally to coil 30. 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 grains 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 U.S. Pat. No.
3,260,505 to VerSnyder. Grain growth occuring in this manner
produces an [010] radial orientation and [100] tangential
orientation.
Much the same arrangement may be used in producing a more idealized
orientation of grain structure. As shown, in FIG. 2, the axially
extending portion 14' of a 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. In
operation the same procedure is followed as above. When the molten
alloy is poured into the mold, 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.
The resulting orientation is shown in FIG. 3 where the seed 36 is
made up of wedges, for example, as shown, the seed is made up of
eight wedges each of 45.degree. and each having the orientation
indicated. The result is a disc made up of interacting dendritic
growths producing approximately a [010] radial and a [100]
tangential orientation. Use of many more wedge elements will
produce a more precisely radial grain distribution within the disc.
Obviously the controlled radial thermal gradient provided by the
structure of FIG. 1 permits controlled grain growth through the
entire disc to its periphery.
One particular article that may prove particularly useful in a
casting of this character is represented by FIGS. 4 and 5. In these
figures is 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 forming projections 46 defining blade-shaped
cavities 48 communicating with the disc cavity as shown in FIG. 5.
Following the method above described, and using the heat
controlling arrangement of FIG. 1, 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
[010] radial orientation in the blades for the desired strength
characteristics. In this arrangement the number of seed wedges
would be selected to insure the precise radial grain growth in the
blades. Thus, for example, 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.
Another alternative is shown in FIGS. 6 and 7 where the mold is
made up of individual mold elements 50 extending 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.
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. Obviously 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.
* * * * *