Method and apparatus for manufacturing a multi-alloy cast structure

• US 10,449,605 B2
• Filed: 11/07/2014
• Issued: 10/22/2019
• Est. Priority Date: 11/27/2013
• Status: Active Grant

• Current Assignee: Rtx Corporation
• Original Assignee: United Technologies Corporation (Rtx Corporation)
• Inventors: Bullied, Steven J., Marcin, Jr., John J., Kreek, Emily K., Verner, Carl R., Bochiechio, Mario P.
• Primary Examiner(s): Kerns, Kevin P
• Assistant Examiner(s): Ha, Steven S
• Application Number:
  US15/036,214
• Publication Number:
  US 20160288201A1
• Time in Patent Office: 1,810 Days
• CPC Class Codes: B22C 9/06 Permanent moulds for shaped castings moulds for ingots B22D7/06
• CPC Class Codes: B22C 9/082 Sprues, pouring cups
• CPC Class Codes: B22C 9/24 for hollow articles
• CPC Class Codes: B22D 19/16 for making compound objects cast of two or more different metals, e.g. for making rolls for rolling mills casting compound ingots B22D7/02
• CPC Class Codes: B22D 21/005 with high melting point, e.g. Be 1280 degrees C, Ti 1725 degrees C
• CPC Class Codes: B22D 25/02 by its peculiarity of shape; of works of art cylinders, pistons B22D15/02
• CPC Class Codes: F01D 5/147 Construction, i.e. structural features, e.g. of weight-saving hollow blades F01D5/148, F01D5/16 and F01D5/20 take precedence; blade shape F01D5/141; blades with cooling or heating channels or cavities F01D5/18; heating, heat-insulating or cooling means on blades F01D5/18
• CPC Class Codes: F05D 2230/21 by casting

Abstract

A method casts a plurality of alloy parts in a mold (600; 700) having a plurality of part-forming cavities (601). The method comprises pouring a first alloy into the mold causing: the first alloy to branch into respective flows along respective first flowpaths (676, 684; 708) to the respective cavities; and a surface of the first alloy in the part-forming cavities to equilibrate. The method further comprises pouring a second alloy into the mold causing: the second alloy to branch into respective flows along respective second flowpaths (676, 680; 712) to the respective cavities.

Claims

1. A method for casting a plurality of alloy parts in a mold (600;

700) having a plurality of part-forming cavities (601), the method comprising;

pouring a first alloy into the mold causing;

the first alloy to branch into respective flows along respective first flowpaths (676, 684;

708) to the respective cavities; and

a surface of the first alloy in the part-forming cavities to equilibrate via a first passageway (694;

718) linking the first flowpaths; and

pouring a second alloy into the mold causing;

the second alloy to branch into respective flows along respective second flowpaths (676, 680;

712) to the respective cavities.

2. The method of claim 1 wherein:

the first passageway comprises a plurality of segments (695) each directly connected to a pair of downsprues.

3. The method of claim 1 wherein:

the first passageway comprises a plurality of segments (720) each directly connected to a pair of grain starters.

4. The method of claim 1 wherein:

said pouring said second alloy into the mold causes a surface of the second alloy in the part-forming cavities to equilibrate via a second passageway (692) linking the second flowpaths.

5. The method of claim 1 wherein:

the first flowpaths and second flowpaths extend from a single pour cone.

6. The method of claim 5 wherein:

each of the first flowpaths is partially overlapping with an associated one of the second flowpaths.

7. The method of claim 1 wherein:

after the equilibrating of the first alloy, but before the pouring of the second alloy, the first alloy along at least portions of the first flowpaths solidifies.

8. The method of claim 1 wherein:

the first alloy and the second alloy are of different composition.

9. The method of claim 1 further comprising:

pouring a third alloy into the mold.

10. The method of claim 1 wherein:

the first flowpaths and second flowpaths extend from first ports on a pour cone; and

third flowpaths extend from second ports on the pour cone.

11. The method of claim 10 wherein:

the pour cone is a dual concentric pour cone having an inner pour cone and an outer pour cone;

the first ports are on one of the inner pour cone and the outer pour cone; and

the second ports are on the other of the inner pour cone and outer pour cone.

12. The method of claim 1 wherein:

the alloy parts are turbine engine blades.

13. The method of claim 1 wherein:

the first alloy and the second alloy are nickel- and/or cobalt-based superalloys.

14. A casting mold (600;

700) comprising;

a plurality of part-forming cavities (601), each having a lower end and an upper end;

a pour cone;

a plurality of first feeder passageway sections (684;

708) extending to associated first ports (685) on respective associated said cavities;

a first passageway (694;

718) connecting the part forming cavities at a height below tops of the part-forming cavities; and

a plurality of second feeder passageway sections (680;

712) extending to associated second ports (681) on respective associated said cavities, the second ports being higher than the first ports.

15. The casting mold of claim 14 further comprising:

the first passageway (694) connects the part forming cavities via the first feeder passageway sections.

16. The casting mold of claim 14 further comprising:

a second passageway (692) connecting the second feeder passageway sections.

17. The casting mold of claim 16 wherein:

the first feeder passageway sections and the second feeder passageway sections branch from trunk passageway sections (676) extending downward from the pour cone.

18. The casting mold of claim 16 wherein:

the first passageway is below the second passageway.

19. The casting mold of claim 14 further comprising:

a plurality of third feeder passageway sections (674) extending to associated third ports (675) on respective associated said cavities.

20. The casting mold of claim 19 wherein:

the third ports (675) are above the second ports (681).

21. The casting mold of claim 19 further comprising:

first flowpaths through the first feeder passageway sections to the first ports and second flowpaths through the second feeder passageway sections to the second ports extend from a first ports (671) on the pour cone; and

third flowpaths through the third feeder passageway sections to the third ports extend from second ports (673) on the pour cone.

22. The casting mold of claim 14 wherein:

a first passageway comprising the first feeder passageway sections and a second passageway comprising the second feeder passageway sections extend fully around a central vertical axis (571) of the mold.

23. The casting mold of claim 14 wherein:

there are 3-40 said cavities.

24. The casting mold of claim 14 wherein:

the cavities are blade-shaped.

25. The casting mold of claim 14 wherein one or both:

the cavities have seeds (633); and

the cavities comprise helical grain starter passageways (634).