U.S. patent number 3,714,977 [Application Number 05/165,619] was granted by the patent office on 1973-02-06 for method and apparatus for the production of directionally solidified castings.
This patent grant is currently assigned to United Aircraft Corporation. Invention is credited to Bruce E. Terkelsen.
United States Patent |
3,714,977 |
Terkelsen |
February 6, 1973 |
METHOD AND APPARATUS FOR THE PRODUCTION OF DIRECTIONALLY SOLIDIFIED
CASTINGS
Abstract
In making directionally solidified castings, a vertically
movable radiation shield is supported in such a way that it may
move upwardly with respect to the mold and the mold heater to
permit upward movement of the mold and the supporting chill plate
into the surrounding heater but upon retraction of the mold from
the heater the radiation shield will be supported adjacent to the
lower end of the heater and continued downward movement of the mold
will withdraw the latter through the shield.
Inventors: |
Terkelsen; Bruce E. (Cheshire,
CT) |
Assignee: |
United Aircraft Corporation
(East Hartford, CT)
|
Family
ID: |
22599683 |
Appl.
No.: |
05/165,619 |
Filed: |
July 23, 1971 |
Current U.S.
Class: |
164/122.1;
164/125 |
Current CPC
Class: |
B22D
27/045 (20130101) |
Current International
Class: |
B22D
27/04 (20060101); B22d 027/06 () |
Field of
Search: |
;164/60,125,136,338,348 |
References Cited
[Referenced By]
U.S. Patent Documents
Other References
"Process Speeds Up Directional Solidification," Erickson et al.,
Metal Progress, March, 1971, pp. 58-60..
|
Primary Examiner: Overholser; J. Spencer
Assistant Examiner: Roethel; John E.
Claims
I claim:
1. Casting apparatus for directionally solidified articles
including
a cylinder providing an enclosure,
means for heating said cylinder to impart heat to a mold in said
enclosure,
a chill plate located at one end of said cylinder on which the mold
is positioned,
means for moving said chill plate relative to said cylinder for
withdrawing the mold from said cylinder,
a radiation shield extending inwardly from the cylinder at the base
thereof and overlying the chill plate, said shield extending
inwardly substantially to a mold on said chill plate, and
stop means for limiting the downward movement of the radiation
shield beyond a point substantially coinciding with the base of the
cylinder, the outer periphery of the shield being slightly spaced
from the cylinder to permit upward movement of the shield within
said cylinder.
2. Apparatus as in claim 1 in which the inner periphery of the
shield conforms closely with the configuration of the mold but
slightly spaced therefrom so that the mold may be withdrawn through
said shield.
3. Apparatus as in claim 1 in which the cylinder is a susceptor and
the heating means is a surrounding induction coil.
4. In the casting of the directionally solidified articles, the
steps of
positioning a shell mold for the article on a chill plate,
providing a heating means surrounding said mold for heating said
mold to a temperature above the melting point of the alloy to be
cast,
cooling the end of the mold resting on the chill plate pouring
molten alloy into the mold,
withdrawing the mold partially from the heating means for more
rapid cooling of the mold than is accomplished by the chill
plate
providing a barrier closely surrounding the mold and movable
relative thereto to define, as the mold is withdrawn from the
heating means, a dividing line between the cooled and heated
portions of the mold,
supporting said barrier on said chill plate so that the latter with
the mold thereon may be moved upwardly into the heating means,
and
limiting the downward movement of the barrier to a point adjacent
the lower end of the heating means as the mold is withdrawn from
the heating means.
5. The process of claim 4 including the step of withdrawing the
mold past the barrier substantially at the rate of solidification
of the alloy.
6. The process of claim 4 including the step of withdrawing the
mold past the barrier at such a rate as to maintain a liquid-solid
interface at a selected distance above the barrier during the
solidification of the alloy.
7. Casting apparatus as in claim 1 in which the radiation shield is
a laminated construction with at least one relatively rigid layer,
and at least one relatively flexible layer with the inner periphery
of the flexible layer extending inwardly beyond the edge of the
rigid layer and substantially into contact with the mold
surface.
8. Casting apparatus as in claim 7 in which the flexible layer is a
graphite felt.
Description
SUMMARY OF THE INVENTION
The copending application of Barrow, et al, Ser. No. 63,143 filed
Aug. 12, 1970, for PRODUCTION OF DIRECTIONALLY SOLIDIFIED CASTINGS,
describes a radiation shield fixed adjacent to the lower end to the
mold heater and closely surrounding the mold thereby to provide for
the retention of heat above the shield and the removal of heat from
the mold below the shield as the mold is withdrawn through the
shield during the solidification process. The present invention is
in some respects an improvement in that it allows an upward
movement of the mold further into the hottest zone of the heater
prior to the pouring thereby more effectively heating the portion
of the mold adjacent to the chill plate.
One feature of the invention is a vertically movable radiation
shield by which to permit the greater movement of the mold within
the heater. Another feature is the arrangement for supporting this
shield to permit its upward movement into the heater but to
terminate the downward movement of the shield at a point close to
the bottom end of the heater. Another feature is a process for
casting directionally solidified articles utilizing a radiation
shield of this movable type.
According to the invention, a radiation shield in the form of a
disc with its inner edge closely fitting the mold, is supported
against downward movement at a point adjacent to the bottom end of
the surrounding mold heater and overlies the chill plate. The
shield is so supported that it may move upwardly within the heater
so that the mold and supporting chill plate may be moved upwardly
into the heater thereby to locate the mold in the hottest part of
the heater during the mold heating. In one arrangement the shield
supports are located internally of the heater elements so that
there are no obstructions below the heater to reduce the effective
radiation from portions of the mold below the shield.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a vertical sectional view through an apparatus embodying
the invention.
FIG. 2 is a fragmentary view similar to FIG. 1 with the mold in a
lower position.
FIG. 3 is a view similar to FIG. 1 of a modification.
FIG. 4 is a plot of the temperature profile within the heater.
FIG. 5 is a fragmentary sectional view of the movable baffle.
FIG. 6 is a fragmentary sectional view of a modified baffle.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring first to FIG. 1, the mold 2 which is shown as a gang mold
for the production of two or more directionally solidified articles
at one time, is positioned on a chill plate 4 and is located within
a heating means which includes a cylinder in the form of a graphite
susceptor 6, the latter surrounded in turn by one or more graphite
felt sleeves 8 for insulation purposes and a surrounding insulating
ceramic cylinder 10 which may be a quartz fiberboard sleeve.
Outside of the cylinder 10 is an induction coil 12 which may be
tapped as at 14 midway of the ends 15 to permit a separate control
of the bottom half of the induction coil. In this way either half
or all of the induction coil may be energized at one time for
controlling the heat inside the susceptor. A suitable insulating
cover 16 may be positioned on the upper end of the susceptor and
overlying the cylindrical chamber defined by the susceptor.
Suitable means are provided for withdrawing the chill downwardly to
move the mold relative to the susceptor so that the mold may be
withdrawn more or less out of the cylindrical chamber defined by
the susceptor. The means for withdrawing the chill are not shown
since any of the conventional actuating means as, for example, a
hydraulic device may be utilized.
The particular mold shown is intended for the manufacture of two
turbine blades at one time and to this extent the mold has two
article forming cavities 22 each having a growth zone 24 projecting
therefrom at the lower end and each having a riser 26 at the upper
end. The risers are connected by gates 28 to a central filling
spout 30. The portion of the mold that produces the desired cast
article, the turbine blade, extends between the dot-dash lines 32
shown on the mold. Mold constructions of this general character are
shown, for example, in a patent to Piearcey U.S. Pat. No.
3,485,291. Obviously, other mold assemblies having a greater number
of article forming cavities are equally usable.
The apparatus surrounding the mold may be supported as on posts 34
extending upwardly from a support 36, the latter being, for
example, the floor of a vacuum chamber within which the entire
apparatus is positioned during the casting operations. A radiation
shield 38 in the form of a disc located at the base of the
susceptor sleeve 6 and the sleeve 8 and cylinder 10 projects
inwardly therefrom and has a central opening 40 therein large
enough to permit the upward motion of the chill plate therethrough.
This radiation shield may be supported together with the susceptor
sleeve and other parts of the apparatus as by heat resistant blocks
42 attached to the posts 34 supporting the baffle 38, the latter
also of suitable heat resistant material. In this way, the
radiation shield stays in fixed relation at the bottom of the
susceptor sleeve and permits vertical movement of the chill plate
through this shield during retraction of the mold while
solidification is occurring and also permits upward movement of the
chill plate with the mold thereon through the shield for
positioning the mold in the selected portion of the heater.
A floating radiation baffle 46 surrounds the mold and has its inner
periphery 48 closely adjacent to the mold but of such a diameter
that the mold may move therethrough as will be apparent. The outer
diameter 50 of this shield is of such a dimension that it will move
within the susceptor but will engage and rest upon the radiation
shield 38 and be supported in this position during a downward
movement of the chill plate and mold within the apparatus. This
baffle 46 serves to contain the heat within the susceptor and
prevent direct radiation from the susceptor both to the chill plate
and to the portions of the mold below this baffle during a downward
movement of the mold during this solidification process. When the
baffle 46 comes to rest on the shield 38 and stays in this position
during the remainder of the withdrawal operation, the baffle 46
then serves in the same manner as the fixed baffle described in the
copending application above-identified.
The baffle 46 is preferably a laminated structure as shown in FIGS.
5 and 6. The baffle of FIG. 5 is a layer 47 of shell mold material
with an overlying layer 49 of graphite felt. The two layers are
suitably attached together and the inner periphery of the felt
layer extends inwardly beyond the periphery of the shell mold
material substantially into contact with the mold. Since this felt
is flexible to a degree, the mold may move freely past the edge of
this felt layer, even deforming the latter to some extent if
necessary. With such close contact, there is no significant leakage
of heat around the inner periphery of this felt layer and also no
significant radiation of heat past this baffle. The shell mold disc
may be made by the usual dipping process for making shell
molds.
Alternatively, the baffle may be made as in FIG. 6 and consists of
two discs 47' of refractory metal or alloy such as tantalum or
molybdenum between which is sandwiched a disc 49' of graphite felt.
This arrangement provides a baffle construction that may be readily
adapted to different mold constructions as the sheet metal and felt
may both be readily cut to the desired configuration. In this
arrangement, the felt layer extends inwardly beyond the metal
layers and has its inner edge in contact with or closely spaced
from the mold surface and is flexible enough to conform to
irregularities in the mold surface. The several layers are suitably
secured together to function as a unit.
Under certain circumstances, it has been found difficult to
maintain or obtain the desired temperature in the mold adjacent to
the chill plate by reason of the temperature profile that develops
within the mold heater during the heating of the mold. As shown in
FIG. 4, the temperature is relatively low at the bottom of the
susceptor and becomes higher a short distance above the bottom of
the susceptor. The temperature within the heater then continues to
increase slowly to a point adjacent the upper end of the susceptor.
Above this point the temperature gradually decreases again to the
top of the susceptor. The temperature T.sub.1 represents the
desired mold temperature for pouring the alloy.
It is desirable to have the temperature of the mold immediately
above the baffle 46 closely approximating the pouring temperature
of the alloy. To accomplish this, it is desirable to have the
portion of the mold immediately above the baffle 46 positioned high
enough within the susceptor so that it is exposed to this
temperature within the susceptor as represented by the point
T.sub.1 in FIG. 1. With a floating baffle of the type shown, it is
possible to move the mold upwardly within the susceptor into the
position shown in FIG. 1, so that the point T.sub.1 of the
susceptor and of FIG. 4 will be almost on the same level as the
baffle.
In use, the apparatus is positioned as an entity within a vacuum
chamber so that by evacuation of the chamber the entire apparatus
shown may be evacuated including the volume defined within the
susceptor. When the chamber has been evacuated, the mold is heated
while the parts are in the position of FIG. 1 so that the mold
itself reaches a temperature effectively above the melting
temperature of the alloy to be poured. With the mold and chill
plate in the position of FIG. 1, it is apparent, as above noted,
that the portion of the mold immediately above the baffle 46 is in
a temperature zone such that this portion of the mold will reach
the desired pouring temperature. Positioning of the mold in this
location is made possible by the fact that the baffle 46, being
floating, is thereby so arranged that it may move upwardly from the
supporting shield 38 to permit the mold, chill plate and baffle all
to be moved upwardly into the position shown in this figure. It
will be understood that during the heating of the mold, water is
circulated through the chill plate to prevent damage to the latter,
although the temperature of the mold relatively close to the chill
plate is successfully raised to a temperature above that at which
the alloy is poured.
The mold is kept in this position while the alloy is poured into
the mold, the temperature of the latter being preferably from
200.degree.-300.degree. F above the normal melting temperature.
After the alloy is poured into the mold, the chill plate and mold
are kept in the position in FIG. 1 for a short time, for example,
five minutes, to allow solidification to start upward from the
chill plate. At the end of this time interval, withdrawal of the
mold is begun in a downward direction at a continuous rate which
may, for example, be four inches per hour. As the chill plate and
mold are moved downwardly, the radiation shield or baffle 46 moves
with them until the baffle engages the shield 38. Continued
downward movement withdraws the mold from within the baffle 46 and
during the continued movement the baffle serves to function in the
manner of the fixed baffle of the earlier application. This baffle
serves to establish a sharp line of demarkation between the heated
zone, surrounded by the susceptor and the cooling or radiation zone
directly below the baffle. The particular function of making the
baffle movable as above described is to permit upward movement of
the mold further into the susceptor than would be possible if the
baffle were a fixed extension of the shield 38.
The arrangement of FIG. 3 is similar to the arrangement of FIG. 1
except that the supporting blocks for the baffle 38 have been
eliminated and thereby the blockage to the radiation of heat from
the mold below the baffle is minimized. To accomplish this result,
the induction coil 12' is supported on posts 52 but hangers 54
extending downwardly from the top of the posts 52 support the
susceptor 6' and the surrounding sleeve 8' and the insulating
sleeve 10'. These hangers have a bar 56 at the base underlying
these sleeves and supporting them in position. This arrangement has
the advantage that it permits a sharper line of demarkation between
the heated portion of the mold above the baffle 46' and the cooled
portion of the mold below the baffle since radiation of heat from
the mold below the baffle is not impeded by the supporting blocks
shown in FIG. 1.
The baffle 46' is similar to the baffle 46 having an inner
periphery closely fitting the mold and an outer periphery to move
within the susceptor but to rest on the inner ends of the bars 56
which project inwardly beyond the susceptor 6' as the mold is
withdrawn downwardly. Once the mold begins to be exposed below the
baffle 46' when the latter comes to rest on the bars 56 as the mold
is being withdrawn, the mold will radiate heat therefrom to the
surrounding cooled walls of the vacuum chamber at a substantial
rate for rapid cooling of the mold while the portion of the mold
above the baffle will continue to be heated from the susceptor. In
other respects, the functioning of the arrangement of FIG. 3 is the
same as that in FIG. 1.
In casting turbine blades, for example, a turbine blade having a
length including the root portion of 4 and 1/2 inches and a growth
portion of the bottom end of the mold substantially 1 inch long,
the top of the completed cast article would be located at a point
five and one-half inches above the chill plate with the gating end
of the filling spout positioned thereabove. In making the casting,
the alloy is poured into the mold, the latter having been heated to
approximately 2750.degree. F. The alloy is poured at a temperature
of 2800.degree. F which is about 250.degree. above the melting
point of the alloy so that a significant super heat is provided.
After pouring, the chill plate is held in the position shown in
FIG. 1 for about five minutes, for example, to allow solidification
to start upward from the chill plate. At the end of this interval,
withdrawal is begun at a continuous rate of 4 inches per hour and
continued for 4 minutes. At this time the withdrawal rate is
increased to 8 inches per hour. Thirty-eight minutes after pour,
the mold is completely withdrawn at the highest rate permitted by
the machine to a point where the mold can be removed from the chill
plate. It will be understood that the time interval for withdrawing
the mold from the heater during the first portion of the withdrawal
movement will be determined by the position of the chill plate and
mold at the beginning of the casting operation. It will be apparent
that only a small amount of radiation cooling of the mold occurs
until the floating baffle has moved down into contact with the
fixed shield 38 so that portions of the mold will be moved
downwardly and exposed below the floating baffle. Prior to this
time there is no significant amount of cooling occurring on this
part of the mold.
* * * * *