EP3463714A1 - Mould for manufacturing a single-crystal blade by casting, installation and method of manufacture implementing same - Google Patents
Mould for manufacturing a single-crystal blade by casting, installation and method of manufacture implementing sameInfo
- Publication number
- EP3463714A1 EP3463714A1 EP17733496.8A EP17733496A EP3463714A1 EP 3463714 A1 EP3463714 A1 EP 3463714A1 EP 17733496 A EP17733496 A EP 17733496A EP 3463714 A1 EP3463714 A1 EP 3463714A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- blade
- mold
- cavity
- forming
- installation
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
- 238000009434 installation Methods 0.000 title claims abstract description 21
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 21
- 238000000034 method Methods 0.000 title claims abstract description 13
- 239000013078 crystal Substances 0.000 title claims description 4
- 238000005266 casting Methods 0.000 title description 3
- 239000002184 metal Substances 0.000 claims abstract description 25
- 229910010293 ceramic material Inorganic materials 0.000 claims abstract description 6
- 238000007711 solidification Methods 0.000 claims description 12
- 230000008023 solidification Effects 0.000 claims description 12
- 238000000465 moulding Methods 0.000 claims description 3
- 238000011144 upstream manufacturing Methods 0.000 description 12
- 239000000919 ceramic Substances 0.000 description 11
- 238000010438 heat treatment Methods 0.000 description 7
- 230000007547 defect Effects 0.000 description 3
- 238000005495 investment casting Methods 0.000 description 3
- 229910001092 metal group alloy Inorganic materials 0.000 description 2
- 238000010791 quenching Methods 0.000 description 2
- 230000000171 quenching effect Effects 0.000 description 2
- 230000015572 biosynthetic process Effects 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 238000005520 cutting process Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 239000012530 fluid Substances 0.000 description 1
- 230000005484 gravity Effects 0.000 description 1
- 229910001338 liquidmetal Inorganic materials 0.000 description 1
- 239000011148 porous material Substances 0.000 description 1
- 229910000601 superalloy Inorganic materials 0.000 description 1
- 230000000930 thermomechanical effect Effects 0.000 description 1
- 210000003462 vein Anatomy 0.000 description 1
- 239000011800 void material Substances 0.000 description 1
Classifications
-
- 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
- B22C9/22—Moulds for peculiarly-shaped castings
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D27/00—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting
- B22D27/04—Influencing the temperature of the metal, e.g. by heating or cooling the mould
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D27/00—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting
- B22D27/04—Influencing the temperature of the metal, e.g. by heating or cooling the mould
- B22D27/045—Directionally solidified castings
Definitions
- the present invention relates to the general field of foundry parts manufacturing processes.
- the invention relates more particularly to a mold for manufacturing a monocrystalline turbine engine blade by lost-wax casting.
- metal or metal alloy parts which have a controlled monocrystalline structure.
- the blades must withstand significant thermomechanical stresses due to the high temperature and the centrifugal forces to which they are subjected.
- a controlled monocrystalline structure in the metal alloys forming these blades makes it possible to limit the effects of these constraints.
- the blades usually consist of a foot, a platform with spoilers, a blade, a heel provided with spoilers, and wipers.
- the parts of the mold cavity forming in particular the spoilers of the platform and the heel solidify with a some delay compared to other parts of the cavity such as that forming the blade. This delay can cause the appearance of unwanted porosities in the final part.
- the blade may present in certain places and in particular on the leading edge or the trailing edge near the platform or heel, parasitized recrystallized grains. This is not desirable when one wishes to obtain a monocrystalline blade.
- the blades obtained can have a significant variation in size between the wax model and the final part, and can sometimes be deformed or twisted.
- the main purpose of the present invention is therefore to overcome such drawbacks by proposing a mold made of ceramic material intended to be used for molding a turbine engine blade from a molten metal, the blade comprising a foot, a platform, a blade , and a heel, the mold comprising:
- an auxiliary grain duct comprising a first portion and a second portion extending the first portion, said first portion opening at one end in a first portion of the cavity forming the root of the blade and at another end in a second portion of the cavity forming a spoiler of the platform of the blade, said second portion opening at one end in said second portion of the cavity and at another end in a third portion of the cavity forming a spoiler of the blade root.
- auxiliary grain duct makes it possible to minimize the defects introduced previously.
- the auxiliary grain duct makes sure that the platform and the dawn's heel do not solidify last, which reduces the occurrence of porosity-like defects in these portions of the blade.
- the auxiliary grain duct plays the role of a stay that keeps the dawn and rigidifies throughout the manufacturing process. By maintaining it thus, the residual stresses that can remain in the blade are reduced, and the appearance of recrystallized grains after heat treatment is also reduced.
- the inventors have observed that the blade obtained with a mold according to the invention has dimensions that are closer to those desired, compared to a blade made in a mold without auxiliary grain conduit. The inventors have also observed that the blade obtained is less twisted when it is manufactured in a mold according to the invention.
- the auxiliary grain line may be positioned in front of the leading edge or the trailing edge of the blade.
- auxiliary grain duct further limit the thickness of the ceramic shell, which allows it to break more easily and thus reduce the appearance of recrystallized grains:
- the first portion of the auxiliary grain duct extends from a wall of the first portion of the cavity in a direction forming an angle of between 54 ° and 62 ° with said wall,
- the second portion of the auxiliary grain duct extends from the second portion of the cavity in a direction forming an angle of between 110 ° and 115 ° with said second portion
- the second portion of the auxiliary grain duct extends from the third portion of the cavity in a direction forming an angle between 110 ° and 115 ° with said third portion.
- the second portion of the auxiliary grain duct may comprise a flyweight at each of its ends.
- the first portion may include a counterweight at one end.
- the dawn may be an aerospace turbine engine turbine blade.
- the second portion of the auxiliary grain duct may have a necking, that is to say a local narrowing of its section, for example at the middle of said second portion. Indeed, the auxiliary grain duct can break more easily at this necking during demolding.
- the invention also relates to an installation for manufacturing a blade molded from a molten metal, comprising a mold such as that presented above, and means for obtaining monocrystalline grain connected to the mold.
- the means for obtaining monocrystalline grain may comprise a monocrystalline seed or a grain selector conduit.
- the invention finally relates to a method for manufacturing a monocrystalline turbomachine blade, comprising the following steps:
- the method may further comprise a step of heat treatment of the blade obtained.
- This heat treatment makes it possible to relax the residual stresses inside the molded blade which may be due in particular to the molding and solidification of the metal, in order to obtain a stable microstructure and controlled mechanical properties in the final part.
- FIG. 1 is a perspective view of an installation according to the invention
- FIG. 2 is a sectional view of a mold according to one embodiment of the invention.
- FIGS. 3 and 4 are sectional views of molds according to various embodiments of the invention.
- FIG. 5 is a flowchart representing the main steps of a method for manufacturing a monocrystalline blade according to one embodiment of the invention.
- FIG. 1 shows a plant 1 for manufacturing by casting a single-crystal aerospace turbine engine turbine blade according to the invention.
- the installation 1 comprises a bucket 2 through which a molten metal can be poured, the bucket 2 is configured to fill with this metal a mold 3 comprising a cavity 4 here having the shape of an aerospace turbine engine turbine blade.
- the mold 3 comprises, according to the invention, an auxiliary grain duct 5.
- the mold 4 overcomes and is connected to a grain selector duct 6 which makes it possible to obtain a monocrystalline blade after a directed solidification of the metal present in the mold 3.
- the installation shown in Figure 1 is intended to manufacture a single blade, it is of course conceivable to have an installation for manufacturing a plurality of blades.
- FIG. 2 shows a sectional view of the cavity 4 of the mold 3 to which the auxiliary grain duct 5 is connected. It will be noted that in FIGS. 1 and 2, for greater clarity, the ceramic material wall of the installation 1 and the mold 3 has not been shown; in other words, these figures only show the internal parts of the plant 1 or the mold 3 in which a molten metal can be introduced.
- the cavity 4 has the shape of an aerospace turbine engine turbine blade and comprises: a portion 40 forming the root of the blade, a portion 41 forming the platform of the blade, a portion 42 forming the blade of the blade and a portion 43 forming the heel of the dawn.
- the foot portion 40 is connected at its bottom to the grain selector conduit 6.
- the blade extends longitudinally between a foot and a top.
- the platform is positioned on the side of the lower end of the blade, between the foot and the blade, and the heel is positioned at the upper end of the blade, that is to say at the dawn summit.
- the platform extends transversely between a downstream end, also called downstream spoiler, and an upstream end, also called upstream spoiler.
- the heel extends transversely between an upstream end, also called upstream spoiler, and a downstream end, also called downstream spoiler.
- the platform and the heel in particular have the role of defining the flow vein of the gas flow in the turbine.
- the blade extends longitudinally between the platform and the heel, and transversely between a leading edge and a trailing edge.
- the portion 41 of the cavity 4 forming a platform is provided with a subpart 411 forming an upstream spoiler platform, and a subpart 412 forming a spoiler downstream of the platform.
- the spoiler sub-parts 411, 412 have a substantially planar shape and extend substantially in the direction DA.
- the portion 43 of the cavity 4 forming a heel is provided with a sub-portion 431 forming spoiler upstream of the heel (or a first end of the heel), and a sub-portion 432 forming spoiler downstream of the heel (or a second end heel).
- Subparts 431, 432 forming spoilers are substantially planar.
- Subpart 432 forming the spoiler downstream of the heel extends downstream substantially in the direction DA, while the subpart 431 forming the upstream spoiler extends upstream and is inclined relative to the direction DA.
- Part 43 further comprises subparts 433 which generally extend in the direction DR and which are intended to form the darts of the blade.
- the mold 3 comprises an auxiliary grain duct 5 comprising a first portion 51 and a second portion 52 extending the first portion 51.
- the first 51 and second 52 portions of the duct 5 are in fluid communication with each other. the other.
- the first portion 51 opens at a lower end 511 in the portion 40 of the cavity 3 forming a foot, and at an upper end 512 in the sub-portion 412 forming spoiler downstream of the platform.
- the second portion 52 opens at a lower end 521 in the sub-portion 412, here at the same place as the first portion 51, and at an upper end 522 in the sub-portion 432 forming spoiler downstream of the heel.
- the first portion 51 of the duct 5 extends, at its lower end 511, from a downstream wall 401 of the portion 40 of the cavity 4.
- the first portion 51 extends to from the downstream wall 401 at an angle ⁇ with it of about 60 °, this angle ⁇ can be between 54 ° and 62 °.
- the first portion 51 describes a curved or rounded shape between the portion 40 and the sub-portion 412.
- the second portion 52 of the duct 5 extends, at its lower end 521, from the sub-portion 412 forming spoiler downstream of the platform.
- the second portion 52 extends from the sub-portion 412 forming an angle ⁇ with it of about 115 °, this angle ⁇ can be between 110 ° and 115 °.
- the second portion 52 extends from the subpart 432 forming spoiler downstream of the heel.
- the second portion 54 extends from the sub-portion 432 forming an angle ⁇ of about 115 ° with it, this angle ⁇ can also be between 110 ° and 115 °.
- the second portion 52 may have at least partly a circular section of diameter D.
- the second portion 52 may have portions 523 which are remote from the portion 42 of the cavity 3 forming a blade distance L
- the portions 523 here are substantially rectilinear.
- the second portion 52 has, at a middle portion thereof, a constriction 524, corresponding to a local decrease in the diameter of the second portion 52. necking may subsequently allow easier breakage of the second portion 52 of the conduit 5 after directed solidification of the metal, in order to reduce the stresses imposed on the molded blade.
- the first portion 51 may have at its upper end 512 a flyweight 513 visible in Figure 1.
- the second portion 52 may have at its lower end 521 and at its upper end 522 two flyweights 525 and 526 ( Figure 1).
- the weights correspond to an enlargement of the portions 51, 52 of the duct 5 at the spoilers 412, 432. As indicated above, these weights 513, 525, 526 can reduce the appearance of porosities in the spoilers of the molded blade .
- the flyweights make it possible to improve the supply of liquid metal to the parts of the cavity 4 forming the spoilers of the blade, which modifies the cooling isotherms in these parts and reduces the formation of porosities during solidification.
- the duct 5 is positioned on the downstream side of the cavity 4 (that is to say, in particular connected to the sub-parts 412, 432 forming spoiler avals), it is however possible to position on the upstream side by connecting it in particular to the subparts 411, 431 forming spoilers upstream.
- Figures 3 and 4 respectively show the mold 3 presented above and a mold 3 'according to another embodiment of the invention.
- the molds 3, 3 ' are shown provided with their ceramic shell 7.
- the ceramic shells of the molds 3 and 3' are made according to the same procedure to be compared.
- the auxiliary grain duct 5 'of the mold 3' has a first portion 5 which is rectilinear and extends at an angle strictly less than 54 ° from the portion 40, this angle is here of the order of 45 °.
- the duct 5 ' has a second portion 52' which extends the first portion 5 and extends from the sub-portion 412 forming spoiler downstream of the platform with an angle of the order of 90 °.
- the geometry of the duct 5 of the mold 3 (FIG. 3) makes it possible to obtain a thickness e of ceramic shell 7 at the level of the wall of the portion 42 facing the duct 5 which is less than the thickness e_ obtained for the mold 3 '(FIG. 4).
- the installation 1 which has been described above can be made entirely of ceramic material, for example by a lost wax casting process.
- a model of the installation 1 in wax must first be manufactured. Then, this wax model is covered with a ceramic shell by successive quenching in a suitable slip (quenching / stuccoing). The ceramic is then fired and the wax removed to obtain the installation 1 of ceramic material.
- FIG. 5 illustrates the main steps of a method of manufacturing a casting molded from a molten metal implementing a plant 1 such as that described previously.
- the first step E1 of the method consists of filling the mold 3, 3 'of the installation 1 by pouring a molten metal into the installation. To do this, one can pour the metal directly into the bucket 2 of the installation 1, and it can walk by gravity to fill the mold 3, 3 '.
- the second step E2 consists in achieving directed solidification of the metal present in the mold, so as to obtain the molded blade.
- Directed solidification is carried out in a suitable furnace in which the installation is placed.
- the furnace makes it possible to control the growth of the crystallized grains in order to obtain a monocrystalline blade by virtue of the presence of a grain selector duct 6 or a monocrystalline seed.
- the carapace may have already begun to break at the end of the directed solidification. Once the piece is solidified, it can be unchecked. We can then cutting the parts connected to the blade corresponding in particular to the auxiliary grain duct 5, 5 '.
- a last step E3 consisting of a heat treatment which allows in particular to dissipate the residual stresses in the molded part.
- the heat treatment may for example consist in subjecting the blade to a temperature of between 1270 ° C. and 1330 ° C. for a period of between 18 hours and 23 hours. Thanks to the use of a mold 3, 3 'according to the invention, a reduction in the appearance of recrystallized grains following this step has been observed.
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Turbine Rotor Nozzle Sealing (AREA)
- Molds, Cores, And Manufacturing Methods Thereof (AREA)
Abstract
Description
Claims
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
FR1655021A FR3052088B1 (en) | 2016-06-02 | 2016-06-02 | MOLD FOR THE MANUFACTURE OF A MONOCRYSTALLINE DARK BY FOUNDRY, INSTALLATION AND METHOD OF MANUFACTURING THE SAME |
PCT/FR2017/051371 WO2017207933A1 (en) | 2016-06-02 | 2017-06-01 | Mould for manufacturing a single-crystal blade by casting, installation and method of manufacture implementing same |
Publications (2)
Publication Number | Publication Date |
---|---|
EP3463714A1 true EP3463714A1 (en) | 2019-04-10 |
EP3463714B1 EP3463714B1 (en) | 2021-09-29 |
Family
ID=57209518
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP17733496.8A Active EP3463714B1 (en) | 2016-06-02 | 2017-06-01 | Mould for manufacturing a single-crystal blade by casting, installation and method of manufacture implementing same |
Country Status (8)
Country | Link |
---|---|
US (1) | US10576535B2 (en) |
EP (1) | EP3463714B1 (en) |
CN (1) | CN109219489B (en) |
BR (1) | BR112018074832B1 (en) |
CA (1) | CA3025331C (en) |
FR (1) | FR3052088B1 (en) |
RU (1) | RU2730827C2 (en) |
WO (1) | WO2017207933A1 (en) |
Families Citing this family (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN109226691A (en) * | 2018-10-10 | 2019-01-18 | 深圳市万泽中南研究院有限公司 | Manufacturing method, ceramic shell mould and the manufacturing equipment of guide vane |
CN109940131B (en) * | 2019-03-26 | 2020-09-18 | 中国科学院金属研究所 | Method for reducing formation of internal porosity defect of single crystal high temperature alloy blade tenon |
FR3094655B1 (en) * | 2019-04-08 | 2021-02-26 | Safran | A method of manufacturing a plurality of distributor sectors by foundry |
CN113070454A (en) * | 2021-03-16 | 2021-07-06 | 贵阳航发精密铸造有限公司 | Casting device and method for non-preferred orientation single crystal guide hollow blade |
FR3127022A1 (en) | 2021-09-15 | 2023-03-17 | Safran Aircraft Engines | Dawn including added spoilers |
Family Cites Families (8)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US5489194A (en) * | 1990-09-14 | 1996-02-06 | Hitachi, Ltd. | Gas turbine, gas turbine blade used therefor and manufacturing method for gas turbine blade |
DE10033688B4 (en) * | 2000-07-11 | 2008-04-24 | Alstom Technology Ltd. | Process for the production of directionally solidified castings |
RU2239520C1 (en) * | 2003-03-21 | 2004-11-10 | Федеральное государственное унитарное предприятие "Всероссийский научно-исследовательский институт авиационных материалов" | Apparatus for making casting of monocrystalline turbine blade |
FR2927270B1 (en) * | 2008-02-08 | 2010-10-22 | Snecma | PROCESS FOR MANUFACTURING DIRECTED SOLIDIFICATION AUBES |
US7918265B2 (en) * | 2008-02-14 | 2011-04-05 | United Technologies Corporation | Method and apparatus for as-cast seal on turbine blades |
GB0901663D0 (en) * | 2009-02-04 | 2009-03-11 | Rolls Royce Plc | Casting method |
FR3002870B1 (en) * | 2013-03-07 | 2015-03-06 | Snecma | PROCESS FOR PRODUCING A ROTOR BLADE FOR A TURBOMACHINE |
FR3006616B1 (en) * | 2013-06-05 | 2016-03-04 | Snecma | TURBOMACHINE WAVE PREFORM |
-
2016
- 2016-06-02 FR FR1655021A patent/FR3052088B1/en active Active
-
2017
- 2017-06-01 US US16/305,326 patent/US10576535B2/en active Active
- 2017-06-01 BR BR112018074832-3A patent/BR112018074832B1/en active IP Right Grant
- 2017-06-01 WO PCT/FR2017/051371 patent/WO2017207933A1/en unknown
- 2017-06-01 CN CN201780033664.XA patent/CN109219489B/en active Active
- 2017-06-01 CA CA3025331A patent/CA3025331C/en active Active
- 2017-06-01 EP EP17733496.8A patent/EP3463714B1/en active Active
- 2017-06-01 RU RU2018146438A patent/RU2730827C2/en active
Also Published As
Publication number | Publication date |
---|---|
CN109219489A (en) | 2019-01-15 |
BR112018074832A2 (en) | 2019-03-06 |
EP3463714B1 (en) | 2021-09-29 |
RU2018146438A3 (en) | 2020-07-10 |
CN109219489B (en) | 2020-10-30 |
US10576535B2 (en) | 2020-03-03 |
RU2730827C2 (en) | 2020-08-26 |
US20190337048A1 (en) | 2019-11-07 |
CA3025331C (en) | 2023-10-03 |
WO2017207933A1 (en) | 2017-12-07 |
BR112018074832B1 (en) | 2022-08-02 |
FR3052088B1 (en) | 2018-06-22 |
CA3025331A1 (en) | 2017-12-07 |
RU2018146438A (en) | 2020-07-10 |
FR3052088A1 (en) | 2017-12-08 |
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