U.S. patent number 3,683,996 [Application Number 05/014,644] was granted by the patent office on 1972-08-15 for method of carbonizing refractory moulds.
Invention is credited to Adam Dunlop.
United States Patent |
3,683,996 |
Dunlop |
August 15, 1972 |
**Please see images for:
( Certificate of Correction ) ** |
METHOD OF CARBONIZING REFRACTORY MOULDS
Abstract
Carbonizing refractory moulds by exposing the moulds to a
carbonizing material while heated to a critical temperature range
extending from the minimum temperature required for dissociation of
the carbonizing material to a higher temperature which is below the
lowest temperature at which the carbonizing material dissociates to
form soot. The preferred mould structure is made by forming a
slurry containing refractory material, a binder and a gelling agent
which is then heated to form a crazed structure. The crazed
structure is strengthened by the addition of a further binder and
the strengthened structure is carbonized. Also disclosed are moulds
formed from a mixture of a refractory material and a silicate
solution which is hardened by means of carbon dioxide before being
impregnated with the pyrolytic graphite. In another embodiment, a
phosphoric acid bond is formed in addition to carbonizing by
impregnating the mould with a furfuryl alcohol solution containing
2 percent by volume phosphoric acid and then heating to
1000.degree. C. or higher in an inert atmosphere.
Inventors: |
Dunlop; Adam (Douglas, Lenark,
SC) |
Family
ID: |
21766769 |
Appl.
No.: |
05/014,644 |
Filed: |
February 26, 1970 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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744818 |
Jul 15, 1968 |
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Current U.S.
Class: |
164/14; 164/72;
164/46; 164/518 |
Current CPC
Class: |
B22C
23/02 (20130101); B22C 3/00 (20130101) |
Current International
Class: |
B22C
3/00 (20060101); B22C 23/02 (20060101); B22C
23/00 (20060101); B22c 003/00 () |
Field of
Search: |
;164/16,41,46,66,67,72,138,259,267,361,14 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
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1,318,796 |
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Jan 1963 |
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FR |
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336,555 |
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Apr 1959 |
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CH |
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Primary Examiner: Annear; R. Spencer
Parent Case Text
This application is a continuation-in-part of my copending
application Ser. No. 744,818 filed on July 15, 1968 and now
abandoned.
Claims
I claim:
1. The method of making a refractory mould having a deposit of
pyrolytic graphite and substantially free of amorphous carbon in
the form of soot, which comprises heating the refractory mould,
while the temperature across the wall thickness of said mould is
within a predetermined range exposing it to a carbonizing material
long enough to impregnate said mould with pyrolytic graphite, said
temperature range extending from a minimum temperature at and above
which said carbonizing material dissociates to deposit pyrolytic
graphite on said mould to a higher temperature which is below that
at which said carbonizing material forms substantial amounts of
soot on said mould.
2. The method set forth in claim 1 in which said mould is exposed
to said carbonizing material at substantially atmospheric pressure,
and said temperature range is further characterized by the fact
that the rates of diffusion and of dissociation of said carbonizing
material are such that pyrolytic graphite is deposited on said
mould and in the pores thereof without sealing the latter.
3. The method set forth in claim 1 which comprises forming a slurry
containing refractory material, a binder and a gelling agent,
heating said slurry to form a crazed structure, and then
strengthening said crazed structure by the addition of a further
binder to form said refractory mould.
4. The method set forth in claim 3 which comprises heating said
refractory mould in an enclosure into which the carbonizing
material is introduced while said mould is at a temperature within
said temperature range.
5. The method set forth in claim 4 in which said carbonizing
material is a hydrocarbon.
6. The method set forth in claim 1 in which a carbonaceous material
is entrained in a carrier gas selected from the group consisting of
an inert gas and air to form said carbonizing material.
7. The method set forth in claim 1 in which the carbonizing
material is made up of a hydrocarbon and phosphoric acid, and said
mould is impregnated with said carbonizing material, whereby a
phosphoric acid bond is formed in addition to the deposit of
pyrolytic graphite.
8. The method set forth in claim 7 in which said hydrocarbon is
furfuryl alcohol.
9. The method set forth in claim 1 in which the carbonizing
material is benzene.
10. The method set forth in claim 1 in which said mould is prepared
by mixing a refractory material with a silicate solution, shaping
the thus formed mixture, and treating the same with carbon dioxide
to harden it.
11. The method set forth in claim 1 in which the carbonizing
material comprises the pyrolyzable reaction product of air and
propane at an elevated temperature.
12. The method of forming a refractory mould impregnated with
pyrolytic graphite and substantially free of amorphous carbon in
the form of soot, which comprises forming a slurry containing
refractory material, a binder and a gelling agent, heating said
slurry to form a crazed structure, further strengthening said
crazed structure by the application of a further binder to form a
mould structure, and then impregnating said mould structure with
pyrolytic graphite.
13. The method as set forth in claim 12 in which said mould
structure is exposed to a carbonizing material comprising furfuryl
alcohol to impregnate the same with pyrolytic graphite.
14. The method as set forth in claim 12 in which said mould
structure is impregnated with graphite by exposing it to a
carbonizing material which comprises the pyrolyzable reaction
product of air and propane at an elevated temperature.
15. The method set forth in claim 12 in which said mould structure
is heated to a temperature within a predetermined range and while
at said temperature is exposed to a carbonizing material long
enough to form a deposit of pyrolytic graphite on said mould and in
the pores thereof without sealing the latter, said temperature
range extending from a minimum temperature at and above which said
carbonizing material dissociates to form said pyrolytic graphite to
a higher temperature which is below that at which said carbonizing
material forms substantial amounts of amorphous carbon.
16. The method as set forth in claim 15 in which said carbonizing
material is benzene.
17. The method set forth in claim 12 in which in impregnating said
mould structure with said graphite a carbonizing material is used
which is made up of a hydrocarbon and phosphoric acid, whereby a
phosphoric acid bond is formed in addition to impregnating said
mould structure with graphite.
Description
BACKGROUND OF THE INVENTION
This invention relates to moulds and cores (hereinafter referred to
for convenience as moulds) that are used in casting, to the method
of forming such moulds and to tools for electric discharge
machining prepared therefrom.
It is known to use refractory materials for making moulds and in
one widely-used process (known commercially as the Shaw process)
wherein a slurry or slurry mixture containing refractory material,
binders and gelling agents is poured into a pattern to form a
gelled refractory mass. This mass is then stripped from the pattern
and subsequently ignited to burn off all volatile constituents. The
mould thus formed may then be heated in a high-temperature oven to
drive off all remaining traces of moisture. It is found that a
mould which is prepared as above described contains a microscopic
network of cracks giving a crazed structure which offers a number
of important advantages when the mould is used for casting. Thus,
there is complete resistance to thermal shock (the cracks closing
slightly to take up thermal expansion when molten metal is poured
into the mould) so that hot metal can, if desired, be poured direct
into cold moulds. Also, the mould possesses very good dimensional
stability so that little or no change of size will occur during the
casting operation. Moreover, a mould produced as above described
will not emit any gas when the molten metal is poured (thus
ensuring that the surface of a casting made in the mould will be
free from gas holes or blemishes) whilst trapped air or gas emitted
by the molten metal will be able to escape through the micro-cracks
in the mould.
Another class of moulds is formed from a mixture of a refractory
material and a sodium silicate solution which is hardened by means
of a hardening agent such as carbon dioxide.
Some metals (such as for example titanium and titanium base alloys)
are extremely reactive at high temperatures and in an attempt to
mitigate the effects of such high reactivity it is also known to
use moulds which are formed of graphite. Such moulds are, however,
expensive or suffer from other disadvantages and accordingly the
object of the present invention is to provide a relatively
inexpensive mould which can be used in the manufacture of precision
castings even though the latter are formed in highly reactive
materials such as titanium and titanium base alloys.
SUMMARY OF THE INVENTION
In accordance with the invention there is provided a mould which is
impregnated with pyrolytic graphite, that is a form of crystalline
carbon, preferably by treatment in a carbonaceous atmosphere under
conditions such that the rate of diffusion of the gas into and
along the interstices of the mould and the rate of dissociation of
the gas to form pyrolytic graphite are such that a deposit of
pyrolytic graphite is formed on the surface and within the pores of
the mould structure while leaving the latter pervious to gases
trapped or evolved in the mould cavity during pouring and casting
of the metal therein. The formation of substantial amounts of soot
or amorphous carbon which would block the pores of the mould
structure and render it impervious to air or gases is avoided.
In accordance with one preferred embodiment of the invention there
is provided a mould which is formed from a slurry containing
refractory material, a binder and a gelling agent and which is
subsequently heated to form a crazed structure, the mould then
being further strengthened by the application of a further binder
and impregnated with pyrolytic graphite. Conveniently, the further
binder is applied by dipping the mould into a liquid solution. The
impregnation of graphite (in the form of pyrolytic graphite) is
preferably achieved by placing the mould in a furnace into which a
gaseous hydrocarbon is admitted. Additional graphite impregnation
may be obtained by incorporating finely divided carbon, which can
be pyrolytic, in the liquid binder solution. Conventional binders,
e.g., organic silicates, are employed.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be more particularly described with
reference to the accompanying drawing wherein;
FIGS. 1A and 1B are sectional elevations which depict one way of
forming a mould,
FIGS. 2A, 2B, and 2C are sectional elevations which show successive
stages of a modified method of forming a mould, and
FIG. 3 is a sectional elevation illustrating one method of
impregnating a mould with pyrolytic graphite.
DETAILED DESCRIPTION
The moulds of the present invention are prepared by providing a
pattern which may be formed of wax or of wood or metal or any other
suitable material, the pattern having a shape similar to the
finished form of the article or part which is to be machined. To
said pattern is applied a binder such as ethyl silicate, a filler
(which may comprise at least one refractory oxide or powdered
graphite or a mixture of at least one refractory oxide and powdered
graphite) and a gelling agent and conveniently these substances may
be applied in turn by dipping the pattern into containers which
contain the substances, the process being repeated until a layer of
material of sufficient thickness is built up on the pattern. After
a sufficient thickness has been built up as aforesaid, the pattern
is removed and the resulting mould is fired to form a crazed
structure in which is formed a network of small cracks. The crazed
mould is then impregnated with graphite in the form of pyrolytic
crystalline carbon and in one example this may be done by passing a
mixture of nitrogen and benzene through a container in which the
mould is placed and which is heated. The benzene then permeates the
mould and by a process of pyrolysis deposits a coating of pyrolytic
graphite on the surfaces and within the crazed structure of the
mould. Instead of using benzene, use may be made of other
substances such as furfuryl alcohol (which may contain finely
divided carbon in solution) which has been refluxed for some time
with dilute hydrochloric acid, the mixture being impregnated into
the mould by immersing the latter in the liquid. The impregnated
mould is then heated in air at a relatively low temperature to
resinify the impregnant and after this the mould is heated in a
vacuum or an inert gas to over 1000.degree. C. to carbonize the
resin. Yet another carbonizing material can be formed by passing a
mixture of air and propane gas over a suitable catalyst as will be
described in detail hereinafter.
Instead of building up the mould as above described, the mound can
be produced by casting a slurry in or around a pattern, the slurry
containing a binder, a filler and a gelling agent. The proportion
of gelling agent will control the setting time of the slurry and
after the latter has set, the pattern is removed from the mould and
then fired to form a crazed structure. The mould is then further
strengthened by the application of a further binder and
subsequently impregnated with graphite as above.
Referring firstly to FIG. 1, a mould is prepared from a suitable
pattern 10 by mounting the pattern on a base 11 which is enclosed
by a peripheral wall 12 and a slurry or slurry mixture containing
refractory material (such as refractory oxides, or silicates, or
carbon or a mixture of these substances), a binder and a gelling
agent is poured over the pattern as illustrated in FIG. 1A. After
gelling has taken place, the pattern, base and peripheral wall are
removed to produce a mould 13 as shown in FIG. 1B and the mould is
then fired to produce a crazed structure as previously referred to.
To further strengthen it, the mould is now dipped in any convenient
liquid binder solution such as a solution of phosphorus pentoxide
in alcohol.
The mould can also be formed as will now be described in connection
with FIG. 2. Initially, there is provided an oversize pattern 14
which is mounted on a base 15 inside a peripheral wall 16 and over
this pattern is poured or rammed a mixture of a refractory material
and a sodium silicate solution which is subsequently hardened by
carbon dioxide to form a backing layer 17 which is made of
relatively inexpensive materials, said layer being formed with a
plurality of apertures 18 which may be provided by suitable cores
or projections on the pattern 14. The oversize pattern 14, base 15
and peripheral wall 16 are then removed and the hardened backing
layer 17 is placed over a second pattern 19 of "finished" size. A
slurry or slurry mixture similar to that already described in
connection with the method illustrated in FIG. 1 is then poured
through the apertures 18 to form an inner layer 20, the pattern 19
being removed after gelling has taken place so that a composite
mould 21 is formed as shown in FIG. 2C. Said mould is then fired to
produce a crazed structure which is further strengthened by the
addition of a further binder by dipping in any convenient liquid
binder as before. The composite mould may, if desired, be washed
after firing with hydrofluoric acid in order to remove any traces
of silica from the mould surface.
Finally, the mould as prepared by either of the above-described
methods is impregnated with pyrolytic graphite. FIG. 3 illustrates
one preferred method of achieving this. Thus, the apparatus shown
in FIG. 3 includes a furnace 22 having a base 23, said base having
an inlet 24 for a carbonizing liquid, vapor or gas. The furnace 22
has an outlet 25 for said carbonizing substance and there is also
provided a cap 26 which is formed of heat resisting steel and which
is placed over moulds 27 (formed as above described) after the
latter have been placed on the base 23, said cap projecting around
its lower edge into a liquid gas seal 28 formed in the base 23.
After said cap 26 has been placed in position, the furnace 22 is
placed over the cap.
An inert gas, such as nitrogen is then passed through the apparatus
until all the air inside has been ejected whilst the furnace
(conveniently of an electrically powered kind) is energized to heat
the moulds 27. The inert gas is then mixed with a carbonizing
liquid, vapor or gas and when the moulds have reached a
sufficiently high temperature (say 800.degree.-1100.degree. C.),
the carbonizing substance will dissociate so that carbon will be
deposited throughout the crazed structure of the moulds.
The minimum temperature required for dissociation of the
carbonizing substance to form pyrolytic graphite is readily
determined in practice for the specific material used. There is a
critical range of temperatures upward from the minimum temperature
required for the formation of the desired pyrolytic graphite, that
is a crystalline form of carbon, in which the process of this
invention is carried out and must not be exceeded. Just above the
upper end of the critical temperature range, instead of
dissociating to form graphite, the carbonizing material forms
amorphous carbon in the form of soot which interferes with and
substantially impairs the accuracy of the moulds in reproducing the
desired castings. In addition, the formation of copious amounts of
soot is not only objectionable for that reason but also because the
soot tends to clog and close the pores of the mould thereby
preventing the escape of trapped air or gas that may be evolved in
the mould cavity during pouring and casting of the metal.
Temperature gradients across the mould wall thickness which could
lead to part of the mould structure being maintained above the
threshold temperature for the formation of soot under the operating
conditions are also to be avoided because the soot which forms in
those parts of the mould tends to destroy its permeability.
Particular care must be taken in the case of monolithic moulds that
are heated from the outside that in spite of the temperature
gradient that may exist across the mould wall, the temperature of
the outer surface and that of the adjacent wall material does not
exceed the critical temperature above which the objectionable soot
is formed. In practice, the limiting temperature which must not be
exceeded for any given set of operating conditions is readily
determined by means of the substantial and readily recognized
formations of soot.
In the operating range of the present invention above the minimum
temperature required for the formation of pyrolytic graphite and
below the higher temperature above which soot forms, the rate of
diffusion of the carbonizing substance and the rate at which
pyrolytic graphite is formed and deposited are such that
crystalline carbon permeates the mould structure without blocking
or destroying its permeability.
After sufficient carbon has been deposited, the supply of
carbonizing substance is interrupted and the inert gas alone passes
through the apparatus. The hot furnace is then removed and the
moulds allowed to cool down to room temperature in the inert
atmosphere inside the cap 26. Instead of using a furnace 22, the
mould can be initially heated to a somewhat higher temperature (say
1000.degree.-1150.degree. C.) in air and then transferred to the
base 23 while hot, the cap 26 being placed over the mould and a
hydrocarbon gas such as methane passed through the cap and over the
mould whilst the latter is cooling down. As was described, care is
exercised in selecting the temperature to which the mould is heated
to ensure that no part of the mould is at a temperature to cause
the formation of unwanted soot.
In accordance with a further embodiment, impregnation by pyrolytic
graphite may be carried out by placing the mould in a container
which is connected by means of a two-way cock to a cylinder of
nitrogen. Said cock is also connected to one flask of a pair of
flasks which are connected together in series and which each
contain benzene, tEe other flask being connected to the aforesaid
container. Thus, the two-way cock can either be set so that
nitrogen passes directly into the container bypassing the flasks,
or alternatively so that nitrogen passes through the flasks
(picking up benzene) before flowing into the container. Initially,
the cock is set to pass nitrogen directly into the container so as
to flush it, and the container is then charged into a furnace when
the cock is turned to pass nitrogen through the benzene and thence
into the container. The benzene deposits onto the mould and within
its pores, by a process of pyrolysis, pyrolytic graphite and it is
found that the mould thus produced is very well suited for the
production of castings of titanium or titanium base alloys, it
being understood that the pyrolytic graphite has unusually high
temperature strength and erosion and corrosion resistance, and is
substantially nonreactive with molten titanium.
In accordance with a further feature of this invention, a mixture
of air and propane gas can be used to provide the carbonizing gas.
A mixture made up of about seven parts by volume of air and one
part propane gas is passed over a catalyst of nickel oxide
(NiO.sub.2) on alumina (Al.sub.2 0.sub.3) at about 1000.degree. C.
to produce a gas, the typical analysis of which is, in percent by
volume, 25% CO, 28% H.sub.2, 2% CH.sub.4 and the balance N.sub.2
plus incidental impurities. To that gas is added propane gas in an
amount equal to about 1 percent by volume of the final mixture
which then forms the carbonizing atmosphere that is fed to the cap
26 as was previously described, the moulds treated being at a
temperature high enough for the formation of pyrolytic graphite but
below the temperature at which the undesired soot is formed.
In accordance with another embodiment of the invention, use may be
made of a furfuryl alcohol solution containing about 2 percent by
volume of phosphoric acid. After impregnating the mould with this
solution, the mould is heated up to 1000.degree. C. or more in an
inert atmosphere so as firstly to develop a phosphoric acid bond
and secondly carbonize the furfuryl alcohol. As before the furfuryl
alcohol/phosphoric acid solution may also contain finely divided
graphite which may be pyrolytic.
As above mentioned, a solution of phosphorus pentoxide in alcohol
may be used as a liquid binder solution but other solutions such as
phosphoric acid in water or sodium silicate solution or hydrolized
ethyl silicate solution may be used instead. Furthermore, finely
divided carbon which can be pyrolytic may be incorporated into any
of these solutions and when thin sections are to be cast in
titanium such finely divided carbon will give a sufficient
impregnation of graphite. When heavier sections are to be cast or
when hot moulds are being used, however, impregnation of pyrolytic
graphite is required in addition.
The process of the present invention does not require the high
temperature and vacuum or pressure conditions of the prior art but
provides for the impregnation of moulds and cores under
substantially atmospheric pressure conditions. The moulds prepared
by the process of the present invention have an even distribution
of graphite impregnant which heretofore has not been
obtainable.
In still a further embodiment, a modified form of mould is prepared
from a mixture of a refractory material and a sodium or potassium
silicate solution which is hardened by means of carbon dioxide or
other hardening agent and then impregnated with graphite, e.g.,
pyrolytic graphite as described hereinabove.
Thus, the present invention will provide a relatively inexpensive
mould which can be used for the casting of metals (such as for
example titanium and titanium alloys) which are extremely reactive
at high temperatures, the graphite impregnation mitigating the
effects of such high reactivity. The moulds will of course be
formed of relatively inexpensive material and will not provide the
highest degree of accuracy or surface finish, but where such
criteria are not required, then, as stated above, a mould formed in
accordance with the present invention will provide an extremely
effective and inexpensive casting aid.
Moulds prepared by the novel method of the present invention are
particularly suitable for use as a tool or electrode in carrying
out electric discharge machining.
Such machining makes use of the phenomenon of spark erosion in
which erosion of metal takes place when a spark crosses between an
electrode or tool and a workpiece, the electrode eroding is own
shape into the workpiece. The electrode or tool to be formed in
accordance with the method of the present invention can be used for
example in machining a die or other metal parts which can either be
cast or rough machined before being further machined by said tool
or electrode.
The moulds of the present invention are thus provided with a
network of finely divided particles of pyrolytic carbon and in some
instances it will be found that the deposition of such pyrolytic
carbon will be sufficient to form an electrically conducting
structure which can be used as the aforesaid electrode or tool. In
this case the aforesaid filler which is used together with the
binder and gelling agent to build up the mould may be in the form
of a ceramic material. As an alternative, however, and as
previously mentioned particles of carbon can be used instead of the
ceramic material so as to enhance the conductivity of the completed
mould if the mould is to be used as a tool in electric discharge
machining. It is also to be understood that the impregnation of the
mould to provide a network of pyrolytic carbon as above described
can be carried out in an convenient way which may vary from the
methods indicated above.
The terms and expressions which have been employed are used as
terms of description and not of limitation, and there is no
intention in the use of such terms and expressions of excluding any
equivalents of the features shown and described or portions
thereof, but it is recognized that various modifications are
possible within the scope of the invention claimed.
* * * * *