EP3326734A1 - Herstellungsverfahren eines keramischen gusskerns - Google Patents

Herstellungsverfahren eines keramischen gusskerns Download PDF

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Publication number
EP3326734A1
EP3326734A1 EP17202768.2A EP17202768A EP3326734A1 EP 3326734 A1 EP3326734 A1 EP 3326734A1 EP 17202768 A EP17202768 A EP 17202768A EP 3326734 A1 EP3326734 A1 EP 3326734A1
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EP
European Patent Office
Prior art keywords
machining
block
core
manufacturing
ceramic
Prior art date
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Granted
Application number
EP17202768.2A
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English (en)
French (fr)
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EP3326734B1 (de
Inventor
Jean-Yves BALDUINI
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Jy'nove Sarl
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Jy'nove Sarl
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Publication of EP3326734A1 publication Critical patent/EP3326734A1/de
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/10—Cores; Manufacture or installation of cores
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/02—Sand moulds or like moulds for shaped castings
    • B22C9/04—Use of lost patterns
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/12—Treating moulds or cores, e.g. drying, hardening
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/18—Finishing

Definitions

  • the present invention relates to a method of manufacturing a ceramic foundry core for the production of a complex cavity hollow casting part by lost-wax casting, such as a gas turbine rotor or stator, of a motor. airplane, reactor, a combustion nozzle or the like, said core being an image of the complex cavity of the hollow part to be manufactured.
  • This lost wax foundry fabrication process is to manufacture a ceramic core having a complex geometry and walls or partitions that can be very thin, of the order of a millimeter, since this core must be hollowed out and perforated. to be able to define the exact and precise interior volume of the hollow part to be manufactured.
  • This ceramic core is preferably made of a technical ceramic material or any other compatible material, that is to say which has a high mechanical strength and a high hardness and which withstands very high temperatures given the temperature of melting of metals and metal alloys which are of the order of 1500 ° C.
  • this technical ceramic material or the like must be able to dissolve chemically to release the complex interior cavity of the hollow part obtained after casting.
  • This ceramic core is intended to be embedded in a wax blank obtained by molding and whose outer geometry defines the external volume of the hollow part to be manufactured.
  • the wax blank is dipped in a ceramic bath to coat it with a hard ceramic shell.
  • the ceramic shell is raised in temperature to the melting temperature of the wax allowing the removal of the wax that flows from the shell leaving inside the shell a negative volume defined between the inner wall of the carapace. the carapace and the outer wall of the inner core.
  • the molten metal is then cast inside the ceramic shell.
  • the outer ceramic shell and the inner core are removed by shaking to clear the resulting hollow part.
  • the foundry technique makes it possible to obtain quality finished parts without any subsequent finishing operation.
  • the ceramic casting cores are manufactured by molding in a multi-drawer mold.
  • the manufacture of the mold is particularly tedious because the prints, which are the negative images of the core to be made, are very complex and make the design of the mold and its manufacture very expensive and very long.
  • the average manufacturing time of such a mold is about a year and represents an investment of about one million euros.
  • One of the techniques consists in providing a contact machining step of a previously molded ceramic core blank, with or without an inner recess.
  • This machining step allows either to machine the recess as such, or to perfect the inner recess already partially produced by molding, or to deburr the blank obtained.
  • the machining step can be carried out either by removal of material such as by milling or by abrasion, as the examples described in the publications FR 2 878 458 A1 , FR 2 930 188 A1 and FR 2 900 850 A1 .
  • Another technique consists in providing a non-contact machining step of a previously molded ceramic core blank, this machining step being performed on a fired ceramic, by laser or ultrasound to perfect the dimensional characteristics of said core, such as the examples described in the publications US 5,465,780 A and WO 97/02914 A1 .
  • the publication WO 2015/051916 A1 proposes to machine on a numerically controlled machine the ceramic core and the outer blank of lost wax disposed around said core without however specify the operating mode given the difficulties in machining said core.
  • the present invention proposes a new manufacturing process for solving the problems mentioned above, to substantially shorten the manufacturing process of the ceramic cores for the lost wax foundry, and correspondingly reduce the investment cost for the purpose. to reduce the cycle and development cost of new gas turbine parts, aircraft engines, engines, combustion nozzles and any complex cavity hollow part, to provide flexibility in the management of industrial projects , to allow an evolution of the geometry of already existing pieces.
  • the development time of the manufacturing method according to the invention can be divided by a coefficient of 10 and its cost by a coefficient of 40 relative to the process of classic molding.
  • This new manufacturing process also allows the production of pre-series and the manufacture of parts on demand.
  • the invention relates to a manufacturing method of the kind indicated in the preamble, characterized in that said core is manufactured by machining a block of cooked ceramic material by mechanical removal of material, in that the operation machining tool comprises at least a first machining step for producing a first machined surface in said block of material, and a second machining step for producing a second machined surface in said block of material, substantially opposite said first machined surface, and in that, prior to said second machining step, is applied to all or part of said first machined surface a reinforcing layer in a stiffening solution to protect said block of material from breakage the second machining step and it is expected solidification of said reinforcing layer before starting the second machining step.
  • the machining operation comprises several machining steps, then the application of a reinforcing layer is renewed before each new machining step on all or part of a surface of said block of material substantially opposite to said new surface to be machined.
  • stiffening solution it is advantageous to use a machining glue in the liquid or semi-liquid state having machinable and dissolvable properties. And one can apply said reinforcing layer in one or more applications of stiffening solution.
  • a block of material having at least two parallel opposite faces arranged to form two clamping faces on which the jaws of a clamping vice are applied is preferably used.
  • the said core may be dipped in a solvent bath, or the said core may be subjected to a temperature corresponding to the melting temperature of the stiffening solution.
  • the said core is suspended from a bracket to allow the removal of the molten stiffening solution by gravity flow.
  • FIGS. 1 to 4 show schematically and in front view several steps of a method of manufacturing a ceramic ceramic core according to the invention, in which the figure 1 illustrates the mounting of a ceramic block between two clamping jaws of a machining machine for machining a first face of a blank of said core, the figure 2 illustrates the application of a stiffening solution on the first machined face of the blank, the figure 3 illustrates the machining of a second face of the blank of said core, located opposite the first machined and stiffened face, and the figure 4 illustrates the removal of the stiffening solution after the machining of the second face of the blank.
  • a machining center may be a numerically controlled multi-axis machining center for producing a plurality of simple to very complex shapes.
  • any other type of mechanical machining machine may be suitable.
  • a five-axis milling center was used which makes it possible to machine complex shapes, which are very common in ceramic cores.
  • the manufacturing method comprises a step of mounting a ceramic block 1 between two jaws 2 of a clamping vise 3 of a machining machine (not shown) in the direction of the arrows F.
  • the ceramic block 1 is a machinable technical ceramic blank, namely a block of fired ceramic, which presents by way of example a hardness equivalent or comparable to that of glass fiber-filled composites.
  • This ceramic block 1 may have a parallelepipedal shape as illustrated, or any other form depending on the general shape of the core 20 to be machined, such as for example a polyhedron, a cylinder.
  • the positioning and indexing of the ceramic block 1 on the machining machine are important to ensure the accuracy of the different machining steps regardless of the number of disassembly and reassembly of said block.
  • the ceramic block 1 when it is parallelepiped, it must have two opposite and parallel clamping faces 4 with a precision for example at most equal to 0.1 mm.
  • the clamping height h of the two jaws 2 on the clamping faces 4 of the ceramic block 1 must be minimal but sufficient to ensure the immobilization of the ceramic block 1, and for example equal to at least 3 mm for a lower block height or equal to 30mm, and beyond this height, equal to at least 10% of the height of said block.
  • the height H of the two jaws 2 must be large and at least equal to 70 mm to facilitate the accessibility of the machining tools to the different faces of the ceramic block 1, and in particular to its underside.
  • the tightening of the ceramic block 1 must be controlled to apply a weak but sufficient clamping force, by example between 1 kN and 5 kN.
  • a torque wrench will be used to tighten the two jaws 2 according to the arrows F.
  • the values indicated above are given by way of example and have no limiting effect.
  • the method of mounting the ceramic block 1 on a machining machine may vary according to the shape of said block. By way of example, if it is cylindrical, a cylindrical chuck will be used and the peripheral base of said block may serve as a reference surface.
  • the machining of the ceramic block 1 is started by producing a reference surface 5 which will allow disassembly and reassembly of the ceramic block 1 with a precision of at most 0.05 mm.
  • a reference surface 5 which will allow disassembly and reassembly of the ceramic block 1 with a precision of at most 0.05 mm.
  • a first machining step can then be performed on a first portion of the ceramic block 1 to produce a first machined surface 6 (see FIG. figure 2 ).
  • this first machined surface 6 was made on the left side (in the figure) of the ceramic block 1 by releasing the corresponding angle of the block and in particular creating cavities 7.
  • the ceramic block 1 Prior to this application, the ceramic block 1 must preferably be cleaned and degreased to remove dust and machining oil and thus allow the adhesion of the stiffening solution to the surface of the ceramic block 1. For this cleaning phase, an automatic washing device adapted to prevent any degradation of the ceramic can be used.
  • the stiffening solution is then applied at least to the first machined surface 6, taking care to fill the cavities 7.
  • This stiffening solution which is preferably a machining glue, can be applied by any suitable means in a or several applications.
  • the thickness of the reinforcing layer 8 obtained must be at least equal to 2 mm to obtain the expected stiffening effect.
  • the stiffening solution can be applied when it is in the liquid state by means of a brush or by gravity by pouring it from a determined height not too high, of the order of a few centimeters, from a container containing a quantity sufficient solution. This technique for applying a stiffening solution in the liquid state is the most suitable for filling cavities 7 more than 2 mm deep.
  • any other method of application may of course be suitable according to the geometry of the machined surface 6 to be stiffened and according to the fluidity of the stiffening solution.
  • the stiffening solution must be able to be cleaned in order to be removed from the ceramic block 1 after machining. If it does not have this faculty, its residues must not make impossible the use nor the functions of the obtained ceramic core. It must also retain its stiffening properties up to a temperature of at least 50 ° C, corresponding to the temperature rise experienced by the ceramic block 1 during machining even with lubrication.
  • Suitable stiffening solutions are, by way of example, existing machining glues such as the adhesive pastes sold under the names Araldite 2011 and Araldite 2012, the machining glue sold under the name Rigidax by the company Paramelt, or any other stiffening solution in pasty or semi-fluid form, adhesive or not, having the following particular characteristics: it must be machinable and dissoluble without causing the dissolution of the ceramic on which it is applied.
  • the solvents which exist and which make it possible to dissolve these machining glues, adhesive pastes or any other stiffening solution may be, by way of example, a universal paint sold under the name Syntilor Chrono 10, a gelled spray cleaner marketed under the acronym 1310, a foaming cleaner sold under the name Sansil, etc. These examples are of course not limiting.
  • the figure 3 illustrates the ceramic block 1 remaining after the second machining step of the process which has been carried out on the right side (in the figure) of the block and during which the corresponding angle of the block has been made to create a second surface of the block.
  • machining 9 This second machining surface 9 is substantially located opposite or at the rear of the first machining surface 6.
  • the terms "opposite” and “rear” must not be interpreted in a restrictive sense .
  • the second machined surface may be the back of the first machined surface forming the front of the core, or the inner face of the first machined surface forming the outer face of the core.
  • the forces and vibrations induced in the ceramic block 1 by the cutting tool or tools are directed towards the first machined surface 6 and may cause breaks in the block However, they will have no detrimental effect on the first machined surface 6 nor on the cavities 7 since they have been protected and filled by the reinforcing layer 8.
  • a stiffening solution for forming a second reinforcing layer 11 at the rear of the third surface 10 to be machined As explained above, the remaining ceramic block 1 must be cleaned and degreased to remove dust and machining oil and thus allow the adhesion of the stiffening solution to the surface of the ceramic block 1. It is applied then the stiffening solution in the angle formed between the first machined surface 6 and the remaining portion of the ceramic block 1 opposite the third surface 10 to be machined.
  • This second reinforcing layer 11 thus allows the maintenance of the core 20 obtained after calibration during a third machining step, namely after separation between the core 20 obtained and the remaining portion of the ceramic block 1 commonly called a heel.
  • the figure 4 illustrates the last step of the manufacturing method according to the invention which corresponds to the cleaning of the core 20 obtained after the third machining step which made it possible to machine the third surface 10 separating the core 20 from the ceramic block 1.
  • the heel of the ceramic block 1 is turned by a quarter turn and held vertically by a holding flange 12.
  • a bracket 13 arranged to support the core 20 by any suitable suspension means such as a link 14 which can pass through the openings of the core 20 to retain it when the stiffening solution has melted.
  • the assembly is placed in a recovery tank 15 resistant at least to a temperature of the order of 200 ° C.
  • the whole is placed in an oven, an oven or the like for at least 3h at least 120 ° C to cause the fusion of the stiffening solution 16 which will flow from the core 20 and the remaining ceramic block 1, by gravity in the bottom of the receiving tray 15.
  • the core 20 will be positioned in such a way that the stiffening solution flows without defiling the areas of the core 20 that were not provided with it. Similarly, we will have the link 14 through the core 20 so as not to damage it.
  • the stiffening solution recovered in the receiving pan 15 can be recycled one or more times according to its degree of impurities.
  • any other assembly and / or technical means for removing the stiffening solution 16 of the machined ceramic core 20 may be suitable.
  • the core can be immersed in a solvent bath.
  • machining the different surfaces of the ceramic block 1 from the top to the low, which preserves the rigidity of said block and use natural diamond cutting tools or super-abrasive type PCD or CBN.
  • the machining operations can be carried out dry or with a soluble cutting oil or other suitable lubricant.
  • the use of a cutting oil reduces the wear of the cutting tool but requires cleaning the ceramic block 1 before each application of the stiffening solution.
  • the cutting conditions must also be adapted to the rigidity of the ceramic block 1 and the core 20 to be machined. If it is not very hollow, of the order of approximately 30% of vacuum, it is possible to maintain high machining conditions, for example greater than 300m / min until the last machining step.
  • the machining conditions should be divided by at least 2. It is still possible to complete the machining of the ceramic block 1 by traditional cutting tools with an ultrasonic pin to machine the weakest parts of the core 20, as for example the milling center Tongtai VU-5 .
  • the invention achieves the goals set, namely the manufacture of a ceramic core only by mechanical machining and without going through a molding step, to greatly shorten the time of completion and reduce production costs.
  • the method of the invention thus allows to consider new developments of faster parts.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
EP17202768.2A 2016-11-29 2017-11-21 Herstellungsverfahren eines keramischen gusskerns Active EP3326734B1 (de)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
FR1661623A FR3059259B1 (fr) 2016-11-29 2016-11-29 Procede de fabrication d'un noyau ceramique de fonderie

Publications (2)

Publication Number Publication Date
EP3326734A1 true EP3326734A1 (de) 2018-05-30
EP3326734B1 EP3326734B1 (de) 2019-08-07

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ID=58609476

Family Applications (1)

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EP17202768.2A Active EP3326734B1 (de) 2016-11-29 2017-11-21 Herstellungsverfahren eines keramischen gusskerns

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US (1) US10758969B2 (de)
EP (1) EP3326734B1 (de)
FR (1) FR3059259B1 (de)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2019068796A1 (de) * 2017-10-04 2019-04-11 Flc Flowcastings Gmbh Verfahren zur herstellung eines keramischen kerns für das herstellen eines gussteils mit hohlraumstrukturen sowie keramischer kern

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP3616806B1 (de) * 2018-09-03 2021-07-28 Johannes + Michael Otto GbR vertreten durch die Gesellschafter Johannes Otto und Michael Otto Verfahren zur herstellung eines modellformkernrohlings, eines modellformkerns und einer feingussform sowie ein giessverfahren zur herstellung eines gussteils mit einer hohlraumstruktur
TWI741705B (zh) * 2020-07-28 2021-10-01 國立中興大學 主軸之外電源供應器

Citations (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5465780A (en) 1993-11-23 1995-11-14 Alliedsignal Inc. Laser machining of ceramic cores
US5565780A (en) 1990-12-19 1996-10-15 Toshiba America Mri, Inc. NMR radio-frequency coil
WO1997002914A1 (en) 1995-07-11 1997-01-30 Extrude Hone Corporation Investment casting molds and cores
WO2001089738A1 (en) 2000-05-24 2001-11-29 Massachusetts Institute Of Technology Molds for casting with customized internal structure to collapse upon cooling and to facilitate control of heat transfer
DE102005021664A1 (de) 2004-05-06 2005-12-01 General Electric Co. Verfahren zur Bildung von Konkavitäten in der Oberfläche einer Metallkomponente und zugehörige Verfahren und Erzeugnisse
FR2878458A1 (fr) 2004-11-26 2006-06-02 Snecma Moteurs Sa Procede de fabrication de noyaux ceramiques de fonderie pour aubes de turbomachines, outil pour la mise en oeuvre du procede
FR2900850A1 (fr) 2006-05-10 2007-11-16 Snecma Sa Procede de fabrication de noyaux ceramiques de fonderie pour aubes de turbomachine
FR2930188A1 (fr) 2008-04-18 2009-10-23 Snecma Sa Procede pour ebavurer une piece en matiere ceramique.
DE102008037534A1 (de) 2008-11-07 2010-05-12 General Electric Co. Verfahren zum Herstellung von Gasturbinenkomponenten unter Verwendung einer einteiligen verlorenen Kern- und Schalen-Modellform
FR2989917A1 (fr) * 2012-04-27 2013-11-01 Carl Procede de fabrication d'un modele destine a etre utilise pour la realisation de pieces en materiau composite
WO2015051916A1 (de) 2013-10-11 2015-04-16 Flc Flowcastings Gmbh Feingussverfahren hohler bauteile

Family Cites Families (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS5117936B1 (de) * 1971-04-01 1976-06-05

Patent Citations (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5565780A (en) 1990-12-19 1996-10-15 Toshiba America Mri, Inc. NMR radio-frequency coil
US5465780A (en) 1993-11-23 1995-11-14 Alliedsignal Inc. Laser machining of ceramic cores
WO1997002914A1 (en) 1995-07-11 1997-01-30 Extrude Hone Corporation Investment casting molds and cores
WO2001089738A1 (en) 2000-05-24 2001-11-29 Massachusetts Institute Of Technology Molds for casting with customized internal structure to collapse upon cooling and to facilitate control of heat transfer
DE102005021664A1 (de) 2004-05-06 2005-12-01 General Electric Co. Verfahren zur Bildung von Konkavitäten in der Oberfläche einer Metallkomponente und zugehörige Verfahren und Erzeugnisse
FR2878458A1 (fr) 2004-11-26 2006-06-02 Snecma Moteurs Sa Procede de fabrication de noyaux ceramiques de fonderie pour aubes de turbomachines, outil pour la mise en oeuvre du procede
FR2900850A1 (fr) 2006-05-10 2007-11-16 Snecma Sa Procede de fabrication de noyaux ceramiques de fonderie pour aubes de turbomachine
FR2930188A1 (fr) 2008-04-18 2009-10-23 Snecma Sa Procede pour ebavurer une piece en matiere ceramique.
DE102008037534A1 (de) 2008-11-07 2010-05-12 General Electric Co. Verfahren zum Herstellung von Gasturbinenkomponenten unter Verwendung einer einteiligen verlorenen Kern- und Schalen-Modellform
FR2989917A1 (fr) * 2012-04-27 2013-11-01 Carl Procede de fabrication d'un modele destine a etre utilise pour la realisation de pieces en materiau composite
WO2015051916A1 (de) 2013-10-11 2015-04-16 Flc Flowcastings Gmbh Feingussverfahren hohler bauteile

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2019068796A1 (de) * 2017-10-04 2019-04-11 Flc Flowcastings Gmbh Verfahren zur herstellung eines keramischen kerns für das herstellen eines gussteils mit hohlraumstrukturen sowie keramischer kern

Also Published As

Publication number Publication date
EP3326734B1 (de) 2019-08-07
US10758969B2 (en) 2020-09-01
FR3059259A1 (fr) 2018-06-01
US20180147622A1 (en) 2018-05-31
FR3059259B1 (fr) 2019-05-10

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