U.S. patent number 3,678,988 [Application Number 05/051,793] was granted by the patent office on 1972-07-25 for incorporation of dispersoids in directionally solidified castings.
This patent grant is currently assigned to United Aircraft Corporation. Invention is credited to Stephen M. Copley, John K. Tien.
United States Patent |
3,678,988 |
Tien , et al. |
July 25, 1972 |
INCORPORATION OF DISPERSOIDS IN DIRECTIONALLY SOLIDIFIED
CASTINGS
Abstract
Inert particles are uniformly dispersed within a molten alloy
while it is being directionally solidified in a mold to cause a
uniform dispersion within the casting, the dispersion being
produced by ultrasonic waves within the molten alloy during
solidification.
Inventors: |
Tien; John K. (Rocky Hill,
CT), Copley; Stephen M. (Madison, CT) |
Assignee: |
United Aircraft Corporation
(East Hartford, CT)
|
Family
ID: |
21973409 |
Appl.
No.: |
05/051,793 |
Filed: |
July 2, 1970 |
Current U.S.
Class: |
164/501;
164/122.1 |
Current CPC
Class: |
B22D
27/08 (20130101) |
Current International
Class: |
B22D
27/08 (20060101); B22D 27/00 (20060101); B22d
027/02 () |
Field of
Search: |
;164/48,49,97,250,55 |
References Cited
[Referenced By]
U.S. Patent Documents
Other References
Hiedemann, Metallurgical Effects of Ultrasonic Waves, Journal of
the Acoustical Society of America, Vol. 26, No. 45, Sept. 1954 pp.
831-842.
|
Primary Examiner: Overholser; J. Spencer
Assistant Examiner: Roethel; John E.
Claims
We claim
1. In the dispersion of inert particles in a casting during
solidification of the alloy of the casting the steps which
involve
mixing the particles into the molten alloy,
generating ultrasonic waves in the molten alloy to obtain a uniform
dispersion of the particles in the molten alloy, and thereafter
maintaining a uniform dispersion of the particles by generating
ultrasonic waves at a lower level in the molten portion of the
alloy during solidification.
2. In the dispersion of inert particles in a directionally
solidified casting during solidification of the alloy of the
casting within the mold the steps of
adding the inert particles to the molten alloy,
generating ultrasonic waves in the molten portion of the alloy to
obtain and to maintain a uniform dispersion of the particles in the
alloy, and
causing a directional solidification of the alloy from one end of
the mold to the other to obtain an oriented grain structure in the
cast article.
3. The process of claim 2 with the added steps of
causing the directional solidification to occur upwardly by the use
of a chill plate at the bottom end of the mold, and
positioning the source of the ultrasonic waves in the molten alloy
remote from the chill plate.
4. The process of casting a directionally solidified alloy with
inert particles therein including the steps of
melting the alloy,
pouring the alloy into the mold,
introducing inert particles into the alloy and mixing the particles
in the molten alloy,
generating ultrasonic waves in the molten alloy at one end of the
mold as the alloy is solidified, and
simultaneously causing a directional solidification of the alloy
from the opposite end in a direction toward the source of the
generated waves.
5. The process as in claim 4 in which the directional
solidification of the alloy is caused by heat removal from the
alloy by a chill plate located at one end of the mold and with the
source of the ultrasonic waves located at the end of the mold
remote from the chill plate and external to the part of the casting
used as the cast article.
6. The process as in claim 1 including the step of solidifying the
alloy within the mold in a direction toward the source of the waves
to force the inert particles in the molten alloy against the
solidification front.
7. The process as in claim 3 including the step of causing the
solidification front to move from the chill plate toward the wave
generator such that the particles in the molten alloy are forced
against the solidification front to be uniformly embedded within
the solidified alloy.
Description
BACKGROUND OF THE INVENTION
Metals and alloys have been strengthened by a dispersion of inert
particles within the alloy, one example of which is a nickel alloy
within which thoria particles have been dispersed. Several methods
have been used without complete success in obtaining uniformity of
particle dispersion particularly when such particles are not
wettable by the alloy in which they are embedded. This is
particularly true in the plane front mode of solidification or in
the cellular front mode.
STATEMENT OF THE INVENTION
One feature of the invention is a process for mixing the particles
uniformly in the alloy and for maintaining the uniformed dispersion
of the particles during the directional solidification. Another
feature is the use of ultrasonic waves generated in the liquid
phase of the alloy to maintain a uniform dispersion and to force
the particles against the solidification front to incorporate such
particles within the solid phase.
Another feature of the invention is a mold apparatus by which the
inert particles may be kept in a substantially uniform dispersion
while the alloy in the mold is being directionally solidified.
According to the invention the particles which may be non-wettable
by the alloy are mixed with the alloy as by a flow of an inert gas
stream carrying the particles. The particles are caused to be
uniformly dispersed by ultrasonic waves generated in the molten
alloy and are kept mixed during directional solidification of the
alloy toward the source of the waves, this source being at the end
of the mold opposite to the chill plate from which the directional
solidification starts and progresses toward the ultrasonic probe
which is positioned in the molten alloy and is the source of the
waves. These waves force the particles and into the solid liquid
interface.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic view of a mold apparatus for casting the
alloy.
FIG. 2 is a diagrammatic showing of the system.
Referring first to FIG. 1, the mold that may be used in the
incorporation of dispersed particles in the casting includes a
growth portion 2 resting on a chill plate 4 and communicating at
its upper end with a root portion 8 of the mold. The mold shown is
used in casting a turbine blade and the mold provides as well as
the root forcing portion 8 a platform portion 10, an airfoil shaped
blade portion 12, and a shroud forming portion 14 at the upper end
of the blade portion. Above the shroud is the open upper end 16 of
the mold which permits filling of the mold in the casting
process.
The mold is positioned within a susceptor 18 surrounded in turn by
a heating coil 20. The latter may be an induction coil preferably
tapped midway of its ends as at 22 in order to provide a separate
temperature control for the top and bottom portions of the mold.
The susceptor rests on the chill plate, being insulated therefrom
by a suitable insulating ring 26.
Positioned in the upper end of the mold during the casting of the
article therein is a probe 28 by which ultrasonic waves may be
generated within the molten alloy during the solidification
process. Obviously the probe 28 is in such a position that it may
be removed from the liquid alloy before the solidification front
reaches a point to encompass the probe. Also shown, but in dotted
lines, is a tube 30 which is projected downwardly into the mold and
is used for the distribution of the particles into the poured alloy
before solidification of the alloy begins. This tube is removed
after the particles have been dispersed within the molten alloy so
that it is not a part of the mold and does not remain therein
during the solidification.
In the casting process, a suitable alloy which has been melted and
raised to a super heat of about 50.degree. F above the melting
point is poured into the mold after the latter has in turn been
heated by the surrounding heating coils to a temperature above the
melting point of the alloy also preferably at least 50.degree. F
above the melting point. Before solidification begins, the tube 30
is inserted in the molten alloy and the particles are forced into
the molten alloy as for example by a stream of inert gas under
pressure in which the particles are carried in suspension. During
the supply of the particles to the molten alloy and after the
particles have been mixed with the alloy, the ultrasonic waves
established by the probe 28 serve to mix the particles uniformly
throughout the molten alloy in the mold. As the solidification of
the alloy begins and progresses upwardly through the article
forming portion of the mold the ultrasonic waves serve to keep the
particles uniformly dispersed within the molten alloy and also
serve to force the particles against and into the liquid solid
interface as the interface progresses upwardly from the chill plate
toward the top of the mold.
Referring now to FIG. 2 the apparatus by which the invention may be
carried out is shown as applied to a mold 32 for making an ingot
although obviously an article mold as in FIG. 1 may as readily be
used. This mold is positioned on a chill plate 34 and is surrounded
by the susceptor 36 which in turn is heated by axially aligned
induction coils 38 and 40. The induction coils are separately
heated as shown for controlling the cooling of the mold.
The particles to be mixed with the molten metal are supplied from a
hopper 42 through an aspirator 44 such that argon or other inert
gas supplied through a pipe 46 having a valve 48 therein will pick
up the individual particles and deliver them through a refractory
tube 48 into the molten metal within the ingot mold 32. The tube is
shown as projecting nearly to the bottom of the ingot and it is
apparent that the effect of the inert gas carrying the particles is
to assure a mixing to some extent of the particles within the
molten metal.
After the particles are dispersed within the molten metal the tube
48 is withdrawn and an ultrasonic vibration is set up by a
refractory probe 50 immersed in the molten alloy. It has been found
that approximately a 20 kilocycle frequency is acceptable. Higher
power levels are used during the mixing than are used during the
solidification after the mixing is completed.
The probe may be supported with its tip in the molten alloy from a
retracting support structure 52 providing for removal of the probe
as the liquid-solid interface approached the tip of the probe
during solidification. The probe may be energized from a variable
frequency and power generator and controller 54.
After sufficient time is allowed for uniform distribution of the
particles through the molten alloy, directional solidification is
initiated within the ingot by reducing or terminating the energy
supply to the lower heating coil and allowing the effect of the
water-cooled chill plate to establish columnar grain growth
upwardly from the plate. As solidification proceeds the ultrasonic
waves force the particles against the liquid-solid interface while
maintaining a uniform distribution of the particles within the bulk
of the liquid phase of the alloy. Although it is not established
why there is a force acting on the particles at the interface the
existence of this force has been demonstrated and the existence of
the force has also be measured experimentally. Obviously as
solidification proceeds, the probe is kept above the liquid-solid
interface so that it does not become a part of the casting.
Furthermore the tube through which the particles are introduced to
the molten alloy will have been removed prior to the start of
solidification.
* * * * *