U.S. patent number 3,844,727 [Application Number 05/045,687] was granted by the patent office on 1974-10-29 for cast composite structure with metallic rods.
This patent grant is currently assigned to United Aircraft Corporation. Invention is credited to Stephen M. Copley, Bernard H. Kear.
United States Patent |
3,844,727 |
Copley , et al. |
October 29, 1974 |
CAST COMPOSITE STRUCTURE WITH METALLIC RODS
Abstract
Macrocomposite structures composed of a low tensile strength
refractory mass surrounding a plurality of single crystal wires,
the refractory mass being prestressed in compression by the single
crystal wires or rods, and the structure made by such process.
Inventors: |
Copley; Stephen M. (Madison,
CT), Kear; Bernard H. (Madison, CT) |
Assignee: |
United Aircraft Corporation
(East Hartford, CT)
|
Family
ID: |
26723081 |
Appl.
No.: |
05/045,687 |
Filed: |
June 12, 1970 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
|
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714736 |
Mar 20, 1968 |
|
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Current U.S.
Class: |
428/596; 428/598;
164/108; 416/230; 29/889.71; 416/224; 416/241R; 428/614 |
Current CPC
Class: |
B22D
19/02 (20130101); Y10T 29/49337 (20150115); Y10T
428/12361 (20150115); Y10T 428/12486 (20150115); Y10T
428/12375 (20150115) |
Current International
Class: |
B22D
19/02 (20060101); B32b 015/02 (); B22d
019/00 () |
Field of
Search: |
;29/183.5,183,192,191.2,191.6 |
References Cited
[Referenced By]
U.S. Patent Documents
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|
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2665881 |
January 1954 |
Smith et al. |
3084421 |
April 1963 |
McDaniels et al. |
3098723 |
July 1963 |
Micks |
3215511 |
November 1965 |
Chisholm et al. |
3219496 |
November 1965 |
Steingrover et al. |
3233985 |
February 1966 |
Kraft et al. |
3427185 |
February 1969 |
Cheatham et al. |
|
Foreign Patent Documents
Primary Examiner: Curtis; A. B.
Attorney, Agent or Firm: Warren; Charles A.
Parent Case Text
BACKGROUND OF THE INVENTION
This is a continuation of Ser. No. 714,736 filed Mar. 20, 1968, now
abandoned having the same inventors.
Claims
1. A cast composite structure comprising
a central body of refractory ceramic material having a plurality of
longitudinally extending passages therethrough,
metallic end elements at opposite ends of the central body, and
metallic rods extending through the passages in said central body
and integral with said end elements, said metallic rods having a
higher rate of thermal contraction than the refractory ceramic
material, and said rods
2. A cast composite structure as in claim 1 in which the rods are
cast
3. A cast composite structure as in claim 2 in which the end
elements are a
4. A cast composite structure as in claim 3 in which the rods
are
5. A cast composite structure as in claim 3 in which the rods
are
6. A cast turbine vane including
a central portion that is airfoil shape in cross-section and of a
refractory ceramic material, said portion having a plurality of
parallel passages extending therethrough from end to end,
metallic end shrouds at opposite ends of and in contact with the
ends of the central portion, and
metallic cast rods extending through said passages and integral
with said end shrouds, said rods having a higher rate of thermal
contraction than the refractory material and thereby placing the
latter in compression as the cast structure cools below the
solidification temperature of the
7. A cast turbine vane as in claim 6 in which each of the rods is a
single
8. A cast turbine vane as in claim 7 in which the shrouds are
columnar grain structure and are integral with the rods.
Description
This invention relates to a process for casting a macrocomposite
structure and to a novel macrocomposite structure. More
specifically, the invention relates to a casting process which
provides a refractory mass which is reinforced with a plurality of
single crystal wires of a high strength alloy, the resultant
macrocomposite structure fabricated thereby having exceptional high
temperature strength and corrosion/erosion properties.
The use of metal-refractory composites has long been recognized as
offering special advantages as structural materials for high
temperature applications. These composite structures have
particular application and provide distinct advantages in gas
turbine engines and the like. In a gas turbine engine the gas
contacting elements of the engine are continuously subjected to a
very severe and complex environment, such as high temperatures,
severe thermal gradients, erosion, and forces which tend to deform
the gas contacting elements. These forces have a particularly
adverse effect on the leading and trailing edges of these gas
contacting elements. As a result of the severe temperature
gradients and other thermal conditions encountered by the gas
contacting elements presently employed in gas turbines, the
permissible operational periods and operating temperatures of these
gas contacting elements are limited considerably.
Composite structures are known in the art, the composite structure
described in U.S. Pat. No. 3,215,511 being a typical example of
these structures. The composite structure described therein and the
structures described in similar prior art generally employ a
structure wherein a ceramic or other similar material is used in
conjunction with a high temperature alloy. The composition of the
structure is such that the high temperature alloy is the
predominant constituent rather than the ceramic or other type
material. While this structure is somewhat of an improvement over
the metal structures generally used, it is still not the ideal in
that the permissible operational periods and operational
temperatures of the structure are still limited, the controlling
factor being the metal alloy and its properties.
The prior art also discloses composite structures which have
application and use in the field of construction; for example,
prestressed concrete. While there is some similarity between these
structures and the present invention these former structures are
not capable of use in high temperature applications, nor do they
have the characteristics of providing high temperature creep
strength and resistance to oxidation, sulfidation and erosion.
SUMMARY OF THE INVENTION
One object of this invention is to provide a novel casting method
for the fabrication of a macrocomposite structure which has high
temperature creep strength, is resistant to oxidation, sulfidation,
and erosion and has favorable impact loading characteristics at low
temperatures.
One feature of the invention is a macrocomposite blade or vane for
a gas turbine in which the airfoil portion of the vane that is in
contact with the hot gas powering the turbine is a non-metallic
heat resistant material reinforced by metallic single crystal rods
extending therethrough and integral with end shrouds on the vane.
More broadly, the macrocomposite structure may have more general
application where the refractory non-metallic structure is exposed
to a very hot environment and is held under compression during use
by the reinforcing single crystal rods extending therethrough and
connected to the metallic end elements on the cast article.
In practicing the process of this invention, molten metal is poured
into a preheated mold and allowed to infiltrate the configuration
of longitudinal holes in a shaped refractory mass, which is
embedded in the mold. After pouring, the temperature gradient in
the mold is controlled so as to promote directional solidification
of the entire melt at a rate consistent with the maintenance of a
cube oriented columnar grain structure. The coarseness of the
columnar grain structure at the base of the refractory part insures
that only single crystals will develop in each of the many
relatively small openings in the refractory mass. The individual
crystals grow together again at the top of the ingot to form once
again the columnar grain structure, as previously described. In
removing the metal refractory composite from the mold it is
extremely important to retain at least a part of the columnar grain
structure at each end, that is, at the top and bottom of the shaped
macrocomposite structure. This latter step is important because
during cooling of the melt, the refractory mass is prestressed in
compression due to a different thermal contraction of the two
materials. Maintenance of the unidirectional columnar structures at
the top and bottom of the refractory metal mass maintains this
beneficial compressive stress developed in the refractory mass
owing to the greater thermal contraction of the metal wires. The
process described herein will be directed at the production or
manufacture of gas turbine parts or gas contacting elements.
However, it is expressly to be understood that the process is not
limited to this type application, macrocomposite structures
fabricated by this process having application in prestressed
pressure vessels, integral gas turbine rotors and other such
applications.
The macrocomposite structure of the present invention is one which
is comprised of a refractory material preferably a ceramic and a
plurality of single crystal metal wires, the wires being preferably
of a nickel or cobalt base. The macrocomposite structure of the
present invention is generally fabricated by the novel casting
process hereinbefore described. As previously noted, during cooling
of the melt, the ceramic or refractory material is prestressed in
compression due to the different thermal contractions of the two
materials. The primary function of the metal wires is load
distribution and protection of the refractory material from
catastrophic failure by thermal shock, or impact loading at low
temperatures, while the primary function of the refractory or
ceramic material is to provide high temperature creep strength and
resistance to oxidation, sulfidation and erosion.
In the novel macrocomposite structure of the present invention, it
is pointed out that there is no bonding between the metal and the
refractory mass, the refractory mass being held in place by either
the flared ends of the metal wires or by the columnar grain
structure which is maintained at the top and bottom of the
macrocomposite structure on removing the macrocomposite structure
from the mold. This latter portion of the macrocomposite structure,
that is, the cube oriented columnar grained section at the bottom
and top of the composite structure, also provides a secondary
effect in that it maintains the beneficial compressive stress
formed in the refractory mass.
The positioning and the numbers of longitudinal holes contained in
the refractory mass is also of significance in the macrocomposite
structure. In certain instances, it would be desirable to have an
inhomogeneous distribution of metal wires within the refractory
mass, this thereby providing the correct number of wires for any
desired stress distribution and stress level. Near the outer
surface a uniformly high level of compressive stress is required to
retard crack initiation and growth in the refractory mass, and
therefore ideally the metal wires should be very fine and closely
spaced. There are limitations on wire size and inter-wire spacing
imposed by both the metal casting and the refractory mass forming
processes. The main limitation on this type construction is that
the component must be designed to have no bending moments. This can
be accomplished by maintaining a relatively constant volume
fraction of metal from the leading to trailing edges. Similarly,
there are applications of the present invention where it would be
desirable to have a homogeneous distribution of metal wires within
the ceramic. Another configuration would be one which has direct
use in a gas turbine engine, this being macrocomposite structure
which has a plurality of cooling air passageways positioned within
the refractory mass. This type configuration provides distinct
advantages in that the level of compressive stress on the
refraction mass would be relatively high even at operating
temperatures. Stress relief within the metal wires would occur at
much lower rates due to the higher creep resistance at lower metal
temperatures.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is an elevation of a cast vane with parts broken away.
FIG. 2 is a vertical section of a preferred mold construction for
use with the novel process of the present invention and with a cast
vane therein.
FIG. 3 is a sectional view through the cast article removed from
the mold substantially along the line 2--2 illustrating a
macrocomposite structure with inhomogeneously distributed
wires.
FIG. 4 is a schematic view similar to FIG. 2 illustrating a
macrocomposite structure with homogeneously distributed metal
wires.
FIG. 5 is a schematic view similar to FIG. 2, showing a
macrocomposite structure illustrating cooling air passages within
the macrocomposite structure.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now in detail to the present preferred embodiments of the
present invention, a preferred form of mold geometry is illustrated
in FIG. 2. The mold construction described herein is particularly
suited for use with any of the so-called superalloys as described
for example in the VerSnyder patent, U.S. Pat. No. 3,260,505. As
therein noted, these alloys are generally adapted for the process
known as directional solidification, the most preferred alloy being
either a nickel base or a cobalt bast alloy. The mold construction
herein described, in addition to the disclosure contained in the
VerSnyder patent, employs the technique of forming
Monocrystaloys.sub.TM as described in Piearcey, U.S. Pat. No.
3,494,709.
As herein illustrated, one end of a tubular mold 4 compatible with
the procedure described in the VerSnyder patent, is placed on a
relatively cool heat conductive and preferably water-cooled plate
6. Water for the chill plate 6 is carried through conduits 8.
Tubular mold 6 is preferably made from a ceramic material from a
conventional slurry of alumina or other high melting point
refractory material in accordance with standard shell-molding
techniques. As illustrated, one end of mold 4 rests on chill plate
6 and cooperates to form an inclosed cavity 10. In communication
with cavity 10 is a passageway 12 through which molten metal is fed
to cavity 10.
Surrounding cavity 10 are the means for heating the mold to the
desired temperature for casting. Preferably the cavity is
surrounded by an electrical resistance heating coil 14 supplied
with variable electrical energy. Alternatively, the cavity may be
surrounded by a graphite susceptor, not shown, and this in turn is
surrounded by an induction coil supplied with high frequency
electrical energy as is usual in an induction furnace. Prior to
casting, the mold is heated to the desired temperature by supplying
energy to coil 14 and when the desired temperature has been
attained, molten metal heated to the proper temperature for casting
is poured into cavity 10. The chill plate 6 is maintained at a
relatively cool temperature by means of water circulating through
conduits 8 so as to establish and maintain a temperature gradient
within the molten metal filling cavity 10 as the metal
solidified.
The cavity 10 within the mold has a lower cavity portion 15 forming
the growth zone for the casting, a shroud portion 22 directly above
the growth zone and directly below the portion 16 of the cavity 10
in which the refractory mass 18 is positioned. Above the mass 18 is
another shroud forming portion 30 and at the upper end of cavity 10
is the filling portion 31.
In the present embodiment, a shaped refractory mass 18 is
positioned in the portion 16 of cavity 10. The shaped vane-forming
mass 18 illustrated the shape of and becomes a part of a nozzle
stator vane for a gas turbine, this being more clearly illustrated
in FIG. 2. The mass 18 is formed of a relatively low tensile
strength refractory mass, the tensile stress being in the range of
20-40 ksi. The casting of the single crystal wires through the
refractory mass permits the use of this relatively low tensile
strength mass; however, it is to be understood that in some
applications a high strength tensile mass may be desired and used
with the invention herein disclosed. The refractory mass has
excellent heat resistant characteristics and is able to withstand
temperatures up to about 1,900.degree.C (3,452.degree.F). It has
been found that an ideal refractory mass would be a ceramic such as
an alumina base material. The refractory mass or shaped element 18
has a plurality of longitudinally extending holes 20 extending
upward from the base portion 22 at the bottom of element 18 to the
top portion 30 at the upper end of the element 18. In order to
promote single crystal growth within the longitudinal openings,
these openings may have a restriction at the bottom or base portion
22 of part 18, or they may just have a relatively small opening at
the base portion. Therefore, after molten metal has been poured
into cavity 10 and it begins to solidify, a controlled columnar
structure forms in the growth zone and forms a columnar grained
shroud 23 in the shroud portion 22 of the cavity 10. By providing a
small opening such as 20 or a restriction, not shown, single
crystal growth is promoted within openings 20 forming single
crystal wires 28, see FIG. 2, which grow within the longitudinal
openings 20. The crystalline growth again becomes columnar in the
shroud 33 formed in the portion 30 of this columnar grain structure
is oriented in the same direction as the columnar grain structure
in the shroud formed at the base of mass 18.
Once the novel casting process described herein has been employed
to permit the growth in the alloy being cast of the shroud 23 with
a cube oriented columnar structure, an intermediate portion of
single crystal wires or rods 28 and a top shroud 33 with
substantially the same columnar structure as the base shroud 23,
the solidified alloy is permitted to cool. As a result of this
cooling, the ceramic or refractory mass 18 is prestressed in
compression due to a differential in the rates of thermal
contraction of the two materials. In other words, the ceramic
element 16 is prestressed in compression due to the greater thermal
contraction of the single crystal metal wires 28. This compressive
stress which is developed in the ceramic vane element 18 is
extremely beneficial in that it inhibits crack nucleation, causes
rehealing of cracks at elevated temperatures, and impairs the
propagation of cracks.
FIGS. 3, 4 and 5 illustrate different embodiments of macrocomposite
nozzle vane structures. FIG. 4 illustrates a vane macrocomposite
structure which positions the single crystal wires 28 substantially
homogeneously within the refractory mass 18. FIG. 3 illustrates an
embodiment where the single crystal wires 28 are positioned
inhomogeneously within the refractory mass 18. This has been found
to be extremely desirable in that it permits a design of a nozzle
vane for the desired stress distribution and stress level. It is
known that near the outer surface a uniformly high level of
compressive stress is required to retard crack initiation and
growth in the ceramic. Ideally the metallic wires should be very
fine and closely spaced; however, there are limitations on wire
size and in the wire spacing imposed by both the metal casting and
the ceramic forming processes. By maintaining a relatively constant
volume fraction of metal from the leading edge to the trailing
edges we have found that a vane may be designed which has no
bending moments, this being a preferred configuration in certain
installations. FIG. 5 illustrates a macrocomposite vane structure
in which, when the vane is incorporated in a gas turbine, the
hollow single crystal wires 28 are cooled by a cooling medium
circulating through central openings 32, this embodiment offering
some distinct advantages. The level of compressive stress on the
ceramic would be relatively high even at operating temperatures.
Stress relief within the metal wires would occur at much lower
rates due to the higher creep resistance at lower metal
temperatures. It is to be understood that where internal cooling of
the metal reinforcing wires is impracticable, the edges of the
airfoil section where the metal wires are of small diameter being
an example, external cooling may be accomplished by forcing air
through small passages around the wires, or in fact, through
passages within the refractory mass itself.
It will be understood that the completed vane as installed in a gas
turbine is the refractory mass 18 together with the metallic
columnar-grained shroud ends 23 and 33 integrally connected by the
single crystal rods or wires. The unused portions of the casting
are removed along the dotted lines 34 and 36. The refractory mass,
being airfoil in shape, forms one wall of a turbine nozzle.
In all of the foregoing embodiments it is to be understood that the
refractory mass 18 is to comprise at least the continuous part of
the macrocomposite structure between the two shroud forming ends
cast in the base portion 22 and top portion 30. More specifically,
the refractory mass in the embodiment illustrated herein would be
continuous or of a one-piece construction of alumina from the
leading edge to the trailing edge of the vane. The constituents of
a preferred macrocomposite structure are illustrated by the
following example:
EXAMPLE I
A macrocomposite structure wherein the refractory mass is a 99
percent alumina (McDanel AP 35, McDanel Refractory Porcelain Co.,
Beaver Falls, Penna.) and the single crystal wires passing through
longitudinal openings within the mass and the shroud elements are
the nickel base superalloy Mar-M-200 (0.15 C, 9 Cr, 10 Co, 2 Ti, 5
Al, 12.5 W, 1.0 Cb, 0.05 Zr, 0.015 B, 1.5 Fe, Bal. Ni).
Longitudinal holes, 0.030 inch diameter, are spaced in a hexagonal
close packed array within the refractory mass. With a
center-to-center spacing of holes equal to 0.053 inch, the
refractory mass will contain 30 volume percent single crystal wires
after casting. The stress in the refractory mass and the wires
are:
.sigma..sub.33 = [(V.sub.2 E.sub.1 E.sub.2)/(E.sub.1 V.sub.1 +
E.sub.2 V.sub.2)].DELTA..alpha..DELTA.T, (1)
and
.sigma..sub.33 = [(V.sub.1 E.sub.1 E.sub.2)/(E.sub.1 V.sub.1 +
E.sub.2 V.sub.2)].DELTA..alpha..DELTA.T (2)
respectively, where
E.sub.1 = average Young's modulus of alumina
E.sub.2 = average Young's modulus of Mar-M-200
v.sub.1 = volume fraction alumina
V.sub.2 = Volume fraction Mar-M-200 wires
.DELTA..alpha. = .alpha..sub.1 - .alpha..sub.2
.alpha..sub.1 = Average linear thermal expansion coefficient of
alumina
.alpha..sub.2 = Average linear thermal expansion coefficient of
Mar-M-200
-.DELTA.t = operational temperature - ambient temperature
It is assumed that the stress in the ceramic and the metal is zero
at the operational temperature.
Taking E.sub.1 = 50 .times. 10.sup.6 psi, E.sub.2 = 16 .times.
10.sup.6 psi, V.sub.1 = 70 v/o, V.sub.2 = 30 v/o, .alpha..sub.1 =
4.3 .times. 10.sup.- .sup.6 .degree.F, .alpha..sub.2 = 7.2 .times.
10.sup.-.sup.6 .degree.F, and -.DELTA.T = 1,800.degree.F,
-.sigma..sub.33 = 32,400 psi
.sigma..sub.33 = 73,800 psi
are the stresses calculated in the ceramic and metal wires
respectively.
It is to be understood that the invention is not limited to the
embodiments herein illustrated and described but may be used in
other ways without departure from the spirit as defined by the
following claims.
* * * * *