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Casting molds for use in directional solidification processes and methods of making

A directional solidification and mold technology, which can be used in self-solidification methods, manufacturing tools, casting and molding equipment, etc., and can solve problems such as easy failure of surface coatings

Inactive Publication Date: 2010-11-17
GENERAL ELECTRIC CO
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Problems solved by technology

Current surface coatings are prone to failure (e.g. when the mold body cracks during the casting process)

Method used

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  • Casting molds for use in directional solidification processes and methods of making
  • Casting molds for use in directional solidification processes and methods of making
  • Casting molds for use in directional solidification processes and methods of making

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Experimental program
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Embodiment Construction

[0013] Disclosed herein are surface coating structures for molds employed in directional investment casting processes. The facecoat structure generally includes a gradient composition including an innermost layer that will contact the cast metal; a sintered layer adjacent to the innermost layer; and an outer release layer near or next to the body of the mold. The innermost and sintered layers are configured to release from the mold at the release layer during the solidification process, wherein the innermost and sintered layers remain bonded to the cast metal surface as the metal solidifies and shrinks away from the mold body. In this way, the separate layers, the innermost layer and the sintered layer, will remain in close proximity and / or contact the cast metal surface as the cast metal cools and protect the cast metal surface from any liquid that penetrates into the mold during the directional solidification process. Metal coolants come into direct contact and react.

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Abstract

Casting molds (10, 56) suitable for directional solidification processes using a liquid cooling bath (60) include a graded facecoat structure (12) on a mold body (20). The graded facecoat structure (12) includes an innermost layer (14) and a delamination layer (18), wherein the delamination layer (18) fractures upon cooling of the molten metal so as to separate the mold body (20) from the innermost layer (14), which remains in contact with or in close proximity to the metal being cast. Also disclosed are directional solidification processes.

Description

technical field [0001] The present disclosure generally relates to casting molds for use in a directional solidification casting process and methods of making the same. More specifically, the casting mold includes a graded surface coating structure configured to prevent or delay reaction of the liquid metal coolant with the cast metal surface during the directional solidification process. Background technique [0002] The directional solidification process is a method commonly used to produce components such as turbine blades and vanes with columnar and single crystal growth structures. It is well known that the high temperature mechanical properties of single crystal superalloys are superior to castings with polycrystalline structures. Typically, the desired single crystal growth structure is established at the base of a vertically disposed mold defining the part. A single-crystal solidification front then propagates through the structure under the influence of a moving t...

Claims

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Application Information

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Patent Type & Authority Applications(China)
IPC IPC(8): B22C9/00B22D27/04
CPCB22D27/045B22C9/04C30B11/002
Inventor S·-C·黄A·J·埃利奥特M·F·X·小吉格利奥蒂R·J·彼得森S·F·鲁特科夫斯基
Owner GENERAL ELECTRIC CO