U.S. patent number 3,700,023 [Application Number 05/063,142] was granted by the patent office on 1972-10-24 for casting of directionally solidified articles.
This patent grant is currently assigned to United Aircraft Corporation. Invention is credited to Anthony F. Giamei, Bruce E. Terkelsen.
United States Patent |
3,700,023 |
Giamei , et al. |
October 24, 1972 |
CASTING OF DIRECTIONALLY SOLIDIFIED ARTICLES
Abstract
The cooling cycle for directionally solidified castings is
improved by lowering the temperature of the mold adjacent to the
chill plate at the beginning of the solidification while
maintaining the high temperature in the greater portion of the mold
and then further cooling the mold near the chill plate during
continued solidification to increase the heat removal and thereby
maintain the desired high thermal gradient.
Inventors: |
Giamei; Anthony F. (Middletown,
CT), Terkelsen; Bruce E. (Cheshire, CT) |
Assignee: |
United Aircraft Corporation
(East Hartford, CT)
|
Family
ID: |
22047203 |
Appl.
No.: |
05/063,142 |
Filed: |
August 12, 1970 |
Current U.S.
Class: |
164/122.2;
164/127; 164/353 |
Current CPC
Class: |
C30B
11/003 (20130101); B22D 27/045 (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: Baldwin; Robert D.
Assistant Examiner: Roethel; John E.
Claims
We claim:
1. In the casting of directionally solidified articles in a mold
the steps of
positioning the mold on a chill plate,
heating the mold to a temperature above the melting temperature of
the alloy,
reducing the temperature of the mold immediately above the chill
plate by the cooling action of the chill plate,
pouring the alloy into the mold,
withdrawing the mold from the heating zone into a cooling zone
having an enclosing wall, and
rapidly further lowering the temperature of certain selected
peripheral areas of the mold by radiation of heat laterally from
said selected areas only through openings in said enclosing wall to
surrounding water cooled surfaces external to said wall thereby
cooling said areas of the mold to a greater extent than the
remainder of the mold to establish in said areas a higher thermal
gradient than is accomplished by the chill plate alone.
2. The method of claim 1 including the steps of
surrounding the mold with a susceptor for heating the mold, and
partially withdrawing the mold from within the susceptor into a
supporting structure below and supporting the susceptor to position
the bottom portion of the mold below the susceptor to expose the
selected areas of the mold through openings in the supporting
structure to the water cooled surfaces when the alloy is poured for
the rapid further cooling of the selected areas of the mold by
radiation.
3. The method of claim 2 including the step of
further withdrawing the mold from within the susceptor to increase
the area of the mold exposed through said openings for a greater
radiation of heat therefrom.
4. The method of claim 1 including the step of continuing the
heating of the top portion of the mold thereby to control the rate
of solidification of the alloy in the mold.
5. The method of claim 2 including the step of
continuing the heating of the portion of the mold within the
susceptor to control the rate of movement of solidification front
within the mold.
6. Apparatus for casting directionally solidified articles
including
a susceptor providing an enclosure for a mold and for heating the
mold,
induction coil means surrounding the susceptor for heating it,
supporting means for said susceptor and coil means,
cooling means in the form of water cooled walls located around said
susceptor and externally of said supporting means,
said supporting means extending downwardly from said susceptor and
between said mold and said walls, said supporting means having
openings therein, said openings being located adjacent those parts
of the mold for which an increased rate of cooling is desired,
means for moving the mold axially of the susceptor to position it
within the susceptor and to withdraw it therefrom and into said
supporting means to permit radiation of heat from said parts of the
mold through said openings to said water cooled walls.
7. Apparatus as in claim 6 including a chill plate on which the
mold is mounted and with which the cooling means cooperates by
receiving radiant heat from the mold, resulting in more rapid
cooling of the mold.
8. Apparatus as in claim 6 in which
the moving means is arranged for positioning the mold with the
chill plate substantially in alignment with the bottom of the
susceptor and for positioning the chill plate below the bottom of
the susceptor to place the lower portion of the mold in a position
to radiate heat through said openings.
Description
BACKGROUND OF THE INVENTION
Directionally solidified articles formed as a single crystal as in
Piearcey U.S. Pat. No. 3,494,709 are most readily produced in shell
molds resting on a chill plate for removal of heat during
solidification and surrounded by heating means to maintain the mold
at a high temperature near the top so that the liquid-solid
interface progresses from the chill plate to the other end of the
mold in a substantially planar form to produce the desired
crystalline or granular structure without spurious nucleation.
STATEMENT OF INVENTION
A feature of this invention is a mold apparatus by which to control
the temperature of the mold more effectively and thereby maintain
the most effective temperature gradient within the mold throughout
solidification of the alloy in the entire mold.
Another feature is an arrangement for additional controlled cooling
of the portion of the mold adjacent to the chill plate at the
beginning of and during the solidification of the alloy for better
control of the thermal gradient. Another feature is a process by
which to produce directionally solidified cast articles free of
such imperfections as freckles. One particular feature is the
control both of the temperature gradient and also of the rate of
solidification that is the rate of upward movement of the
liquid-solid interface during solidification.
According to the present invention, the thermal gradient is
increased by moving the mold partially out of the heating apparatus
into such a position that the lower portions of the mold may
radiate heat and thereby lose heat at a much faster rate than the
chill plate can remove it. To accomplish this suitable openings are
located below the heating apparatus so that heat may be radiated to
the relatively cool wall of the vacuum chamber surrounding the
heating apparatus. Appropriate control of the continued heat input
together with a precise control of the extent to which the mold is
withdrawn permits a high thermal gradient to develop within the
mold and also permits a controlled rate of solidification of the
alloy.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a vertical sectional view through the mold apparatus for
casting single crystal articles.
FIG. 2 is a transverse sectional view along line 2--2 of FIG.
1.
FIG. 3 is a diagram showing the relationship of thermal gradient to
growth rate.
DETAILED DESCRIPTION OF THE DEVICE
As shown in the drawing, the mold assembly 2 is the cocoon type of
mold described and claimed in the copending application of Giamei
et al., Ser. No. 42,423 filed June 1, 1970, and includes two spaced
apart parallelly extending article molds 4. These article molds are
shown as molds for a turbine blade and have an airfoil shaped
portion 6 with a platform portion 8 at the bottom thereof, and a
root forming portion 10 below the platform. Connected to the bottom
of the root portion 10 is a helix portion 11 which serves to select
a single crystal to grow into the article forming portion during
solidification of the alloy. A control mold 12 surrounding and
spaced from the article mold defines chamber 13 between the molds
to be filled with molten alloy in the casting operation for
controlling the rate of cooling in the article mold. This control
mold has an open bottom end to rest on a chill plate 14 and this
bottom end holds the open end of the helix 11 about 1 inch above
the chill plate. The several control molds 12 are interconnected
near their upper ends by gating 15 having a common filling spout
16. The article mold has an open end extension 17 at the top
forming a riser. The article mold is filled by a flow of the molten
alloy downwardly around the article mold and then upwardly through
the helix 11 into the article mold. When the article being cast is
a gas turbine blade or vane, the alloy used is one of the so called
super alloys, examples of which are given in the Piearcey patent
above identified.
The mold assembly when ready to be used for making a casting is
positioned on the chill plate 14 the latter being supported by a
device by which the chill plate with the mold thereon may be moved
upwardly and downwardly with respect to the surrounding apparatus.
The actuating device shown by way of example is a threaded
supporting rod 18 the position of which is controlled by a nut, not
shown that may be driven through suitable gearing by a motor, also
not shown, which permits the chill plate to be moved vertically as
desired and serves, as will be pointed out hereafter, to permit a
precise control of the temperature existing within various portions
of the mold during solidification of the alloy. The motor is
preferably manually controlled for a precise control of the
position and motion of the chill plate.
The mold and chill plate are surrounded by a susceptor 22 in the
form of a cylindrical graphite sleeve which is insulated from a
surrounding heat insulating sleeve 24 by one or more sleeves of
insulation 26 such as graphite felt. Around the sleeve 24 is a
tapped induction coil 28 so arranged as will be apparent that the
top half of the coil may be energized separately from the lower
part of the coil. The total coil surrounds the susceptor and
extends for substantially the same height as the mold within the
susceptor. Clips 30 may attach the coil to the outer sleeve 24 for
supporting the coil in position. The sleeve 24 rests at the bottom
on a base 32.
At the base of the susceptor are one or more rings of insulation 36
such as graphite felt on which the susceptor and insulating sleeve
or sleeves 26 are positioned. The rings 36 rest on a cylinder 38 of
insulation material extending down to the base 32 within the sleeve
24.
The insulating sleeve 24 has openings or windows 40 extending
preferably down to the support 32 and the cylinder from a point
about midway between the insulating rings 36 and the support and
the cylinder 38 has coincident openings 42 generally taller than
the openings 40 as shown. Both sets of openings are located
adjacent to the article portions of the mold as shown in FIG. 2.
The top levels of the openings 40 and 42 are located so that the
mold cannot radiate heat through these openings when the chill
plate is in the position of FIG. 1. Should the gang mold be made
for casting more than two articles at one time, as for example,
four or eight articles there would be a corresponding number of
openings or windows 40 and 42, even to the extent of omitting this
portion of the sleeve 24 and cylinder 38.
The device is normally in the position shown at the start of a
casting operation. The entire unit shown is positioned within a
suitable chamber, represented by the walls 39, preferably a vacuum
chamber since the type of alloy used is preferably cast in a vacuum
and the walls of the chamber are generally water cooled as shown by
the passages 41 in the walls 39. After the chamber is evacuated,
the induction coil is energized for heating the mold to a
temperature above that of the melting point of the alloy to be
cast. When the entire mold with the exception of the portion in
direct immediate contact with the chill plate reaches the desired
temperature above the melting point of the alloy, the alloy is
poured into the mold and immediately before or immediately after
such pouring the chill plate is lowered far enough to expose the
portion of the mold immediately above the chill plate to the
openings or windows 40 and 42. This permits heat to be radiated
from the portion of the mold immediately above the chill plate
directly to the water cooled walls 39 and thereby reduces the
temperature of this part of the mold to a temperature lower than
that obtainable by the cooling function of the chill plate
alone.
With a more rapid chilling of this portion of the mold the
temperature gradient in the mold becomes steeper and the thickness
of the mushy zone, the liquid-solid zone, is thereby decreased. As
the solidification of the alloy within the mold progresses the
chill plate may be moved down in increments to increase the rate of
heat radiation through the windows 40 and 42 thereby maintaining
the high thermal gradient during the solidification of the alloy at
least to a position above the article forming portion of the
mold.
As best shown in FIG. 2 the openings 40 and 42 are located at
points adjacent to the article mold portions 4 thereby providing a
most rapid radiation of heat from these mold portions. It will be
understood that the lowering of the chill plate with the mold
resting thereon not only positions the lower portion of the mold
into alignment with the openings 40 and 42 but also effectively
withdraws this portion of the mold more or less from within the
induction heating coil and thereby reduces or discontinues the heat
input to this portion of the mold.
FIG. 3 shows the effect of the growth rate as compared to the
thermal gradient and the respective areas in which it is possible
to obtain freckle-free directional growth in the form of single
crystal castings. The plot of this figure is deliberately
non-dimensional since the effective thermal gradient above which
freckle-free growth may be obtained is different depending upon the
dimension of the article to be cast, the alloy being used and the
type of mold used in producing the casting. The relative
relationship is however represented in this figure and it
emphasizes that a relatively high thermal gradient is desirable in
producing a single crystal casting free of freckles or other
imperfections in the surface.
Although a high thermal gradient is provided within the alloys as
it solidifies, the solidification rate, that is, the rate of upward
movement of the liquid-solid interface, should be so controlled as
to prevent growth at a rate to cause the alloy to become equiaxed
or randomly crystallized. The slow rate of upward movement of the
liquid solid interface is controlled effectively by the amount of
heat supplied by the induction heating coils to the upper end of
the mold during the casting cycle. If adequate temperature sensing
devices are positioned adjacent to or within the mold structure, as
for example a thermocouple near the top of the mold, another
thermocouple perhaps an inch from the chill plate, and preferably
an intermediate thermocouple it is possible to so determine the
rate of solidification or the rate of cooling of the alloy toward
the solidification temperature that the desired rate of upward
movement of the liquid-solid interface may be precisely
controlled.
As above stated, the type of mold particularly effective for this
purpose is the so-called cocoon mold described above. This
particular type of mold which provides a shell of heat control
alloy effectively surrounding the article being cast for use makes
possible a much more precise rate of movement of the liquid-solid
interface upwardly through the article portion of the mold and also
permits a control of the height of the mushy zone, that is to say
the volume of alloy within the mold between the level where the
alloy is completely solid and the point thereabove where the alloy
is completely liquid. This mushy zone represents that volume that
is partially filled with solid dendritic growth but the alloy
surrounding the dendrites is still unsolidified. The cocoon mold
serves to maintain a substantially flat mushy zone during the
solidification cycle.
It will be understood that there are frequently gang molds having
more than the two mold elements as in FIG. 1 so that there may be a
large number, for example, four or eight or even more article
forming molds interconnected together at the top and each
terminating in an open end at the bottom resting on the chill plate
and all arranged in a ring for simultaneously casting a plurality
of articles. When this occurs, it will be obvious that the
radiation windows, that is to say the openings 40 and 42, form a
greater and greater proportion of the periphery of the cylinder of
insulation 38 and the periphery of insulating sleeve 24 if a
radiation window is provided for each article forming portion of
the mold. To this extent, it may be desirable, where the device may
be used primarily in making a plurality of articles during each
casting operation to extend the openings 40 and 42 to encompass
substantially the entire periphery of the sleeve of insulation
24.
In casting a plurality of single crystal turbine blades at one time
using a cocoon type mold and where the length of the turbine blade
including the root portion was 5 inches, and the helix 12 and
surrounding outer mold formed a lower end extension that was
substantially 11/2 inches long, the top of the completed cast
article that would be used was then located at a point 61/2 inches
above the chill plate. The alloy from which these blades were cast
is an experimental nickel base cast super alloy. The casting
technique was established to produce a single crystal growth
throughout the article portion of the mold so that the finished
article was completely a single crystal from end to end.
To accomplish this with the casting apparatus set up as in FIG. 1
the mold was instrumented with a plurality of thermocouples 44 the
bottom one of which is located about an inch above the chill plate,
the top one is located close to the top of the article forming
portion of the mold and at least one thermocouple is positioned
midway therebetween. In the particular casting process carried out
for producing a turbine blade of the type pictured the
thermocouples were located precisely at points one inch above the
chill plate, at the top end of the article forming portion and at
the blade platform as indicated on the drawing.
With the thermocouples in position the mold was located within the
susceptor and on the chill plate and the entire assemblage was
positioned within a vacuum chamber in order that the casting might
be accomplished under a vacuum. The vacuum chamber having been
evacuated the induction coils were energized to raise the
temperature of the mold to 2,900.degree. F as indicated by the top
thermocouple. During the heating of the mold, cooling water was
circulated at the normal rate, although only enough water may be
circulated through the chill plate to keep the chill plate from
being damaged by the heat.
When the top thermocouple reached the desired temperature, the
chill plate was lowered to obtain a bottom thermocouple temperature
indication of 2,400.degree. F.
The alloy was then poured into the mold, having been heated to
2,850.degree. F which is about 300.degree. above the melting point
of the alloy so that a significant amount of superheat was provided
in the alloy as it was poured.
The normal amount of cooling water that had been flowing through
the chill plate during the heating, was continued during the
solidification process. At the time of pouring the alloy, the
bottom portion of the induction coil was completely de-energized.
As soon as the alloy had been poured and solidification had begun
the energy to the top coil was reduced by increments to reduce the
temperature indicated by the top thermocouple as follows:
40.degree. reduction 10 minutes after pour
40.degree. reduction next 10 minutes after pour
35.degree. reduction next 10 minutes after pour
35.degree. reduction next 10 minutes after pour
35.degree. reduction next 10 minutes after pour
30.degree. reduction next 10 minutes after pour
to reach a temperature of 2,635.degree. F. The indicated
temperature at the completion of the pouring of the alloy into the
mold becomes 2,850.degree., the temperature of the poured alloy.
The bottom thermocouple indicated a temperature of 2,125.degree. F,
60 min. after the alloy was poured. With heat still being supplied
from the top induction coil and from the susceptor, the temperature
of the top of the mold reached at 2,635.degree. F, 60 min. after
pour and the temperature of the middle thermocouple was at
2,400.degree. F at this time thereby indicating that the thermal
gradient was very steep in the portion of the mold where
solidification was going on. With the exposure of the lower most
portion of the mold to the windows so that radiation may take place
the temperature was effectively lowered rapidly. The effect of the
lowered temperature near at the bottom of the mold by radiation
through the windows is to produce a thermal gradient within the
alloy as great as 125.degree. F per inch.
After the first 60 minutes following pouring of the alloy, the
chill was dropped further from the position at pour in increments
of one-fourth inch and this was done at intervals of 10 min. It is
essential that the downward motion of the chill be so controlled
that the bottom of the dendrite field must be above the top of the
radiation window by a pre-determined amount preferably about 2
inches and the timing of the downward motion of the chill must be
such that the dendrite field remained in this relation to the top
of the window. The bottom of the dendrite field will be understood
to be the level where the complete alloy is solidified. It will be
understood that in castings of this character the dendrites within
the alloy grow vertically and horizontally within the mushy zone
and are surrounded by unsolidified alloy within the mushy zone. By
maintaining a steep thermal gradient within the mold, the height of
this mushy zone is made relatively thin and this steep thermal
gradient assures crystallization in the desired form.
During the solidification of the alloy, heat was continuously added
from the top coil to the portions of the mold still within the
susceptor and this coil was de-energized 200 min. after the alloy
was poured. At this time, further heating of the mold was thus
discontinued and the cycle was completed after the total downward
movement of the chill plate had reached 3 inches and this occurred
180 min. after the alloy was poured. The top thermocouple reached a
temperature of 2,200.degree. F 200 min. after the alloy was poured
and this temperature indicated that the solidification of the alloy
had reached a point above the top of the article portion of the
mold.
After the mold and alloy were cooled sufficiently, the mold was
removed from the rest of the apparatus, the casting was removed
from the mold and the article portion of the casting was removed
from the remainder. The result was a cast article all of a single
crystal.
In the apparatus used in the foregoing casting procedure, each
window 42 had its upper edge one-half inch below the starting
position of the chill plate and each opening 40 had its upper edge
11/2 inches below this position of the chill plate. The openings 42
were 4 inches wide and the openings 40 were 5 inches wide. The mold
was positioned so that the convex side of the blade portion of the
mold faced outwardly so that radiation occurred more effectively on
that side of the mold. It will be understood that the cooling of
the mold by radiation is enhanced by the temperature of the walls
of the vacuum chamber to which the mold is exposed more or less
through the windows. These chamber walls are generally water cooled
during the use of the chamber.
The effectiveness of the present apparatus and method is enhanced
by the ability to control the steepness of the thermal gradient and
to have a much steeper thermal gradient than is usually obtainable
in this type of casting. Furthermore with the steep thermal
gradient, the rate of upward movement of the liquid-solid interface
may be controlled by the extent of the radiation provided and also
by the extent of the continued heat input during solidification of
the alloy. It will be apparent that the steepness of the thermal
gradient may be relatively independent of the rate of upward
movement of the solidification front. By the use of the
above-described apparatus, the extremely steep thermal gradient is
obtained and a very effective control of the rate of solidification
so that the solidification will occur in such a manner as to assure
that a single crystal article will be produced.
* * * * *