Centrifugal casting of titanium alloys with improved surface quality, structural integrity and mechanical properties in isotropic graphite molds under vacuum

• US 6,776,214 B2
• Filed: 10/01/2003
• Issued: 08/17/2004
• Est. Priority Date: 06/11/2001
• Status: Expired due to Term

• Current Assignee: Santoku Corporation (Proterial Ltd.)
• Original Assignee: Santoku America, Inc. (Oaktree Capital Management LP)
• Inventors: Scott, Donald W., Ray, Ranjan
• Primary Examiner(s): Stoner, Kiky
• Assistant Examiner(s): LIN, ING HOUR
• Application Number:
  US10/674,435
• Publication Number:
  US 20040060685A1
• Time in Patent Office: 321 Days
• Field of Search: 164/286, 164/289, 164/361, 164/267, 164/529, 164/114, 164/116, 164/117, 164/72
• US Class Current: 164/286
• CPC Class Codes: B22C 3/00 Selection of compositions for coating the surfaces of moulds, cores, or patterns
• CPC Class Codes: B22C 9/02 Sand moulds or like moulds for shaped castings
• CPC Class Codes: B22D 13/00 Centrifugal casting; Casting by using centrifugal force
• CPC Class Codes: B22D 13/101 Moulds
• CPC Class Codes: B22D 21/005 with high melting point, e.g. Be 1280 degrees C, Ti 1725 degrees C
• CPC Class Codes: B22D 21/025 Casting heavy metals with high melting point, i.e. 1000 - 1600 degrees C, e.g. Co 1490 degrees C, Ni 1450 degrees C, Mn 1240 degrees C, Cu 1083 degrees C
• CPC Class Codes: C22C 14/00 Alloys based on titanium

Abstract

Methods for making various titanium base alloys and titanium aluminides into engineering components such as rings, tubes and pipes by melting of the alloys in a vacuum or under a low partial pressure of inert gas and subsequent centrifugal casting of the melt in the graphite molds rotating along its own axis under vacuum or low partial pressure of inert gas are provided, the molds having been fabricated by machining high density, high strength ultrafine grained isotropic graphite, wherein the graphite has been made by isostatic pressing or vibrational molding, the said molds either revolving around its own horizontal or vertical axis or centrifuging around a vertical axis of rotation.

Claims

1. A centrifugal casting apparatus for casting metal products comprising,

a central sprue for rotating along a vertical axis of the central sprue,

isotropic graphite molds which have cavities,

horizontal runners for passing a melt there through under the action of centrifugal force radially outward into the cavities of the molds spinning along a circumference of a circle of rotation, and

means for rotating the isotropic graphite molds.

2. The apparatus of claim 1, wherein the isotropic graphite mold comprises machined graphite, wherein the graphite has been isostatically or vibrationally molded and has ultra fine isotropic grains between 3-40 micron, a density between 1.65 and 1.9 grams/cc, flexural strength between 5,500 and 20,000 psi, compressive strength between 12,000 and 35,000 psi, and porosity below 15%.

3. The apparatus according to claim 2, wherein the isotropic graphite mold comprises at least two isotropic graphite portions which are releasably attached to each other such that a metal product cooled within the mold can be removed from the mold.

4. The apparatus according to claim 1, wherein the isotropic graphite mold comprises at least two isotropic graphite portions which are releasably attached to each other such that a metal product cooled within the mold can be removed from the mold.

5. The apparatus according to claim 2, wherein a coating of either hafnium carbide or tungsten or rhenium is deposited on the surface of each cavity.

6. A centrifugal casting apparatus for casting metal products comprising,

a central sprue for rotating along a vertical axis of the central sprue,

isotropic graphite molds which have cavities,

horizontal runners for passing a melt there through under the action of centrifugal force radially outward into the cavities of the molds spinning along a circumference of a circle of rotation, and

means for rotating the isotropic graphite molds and means for disassembling the mold under vacuum and ejecting the casting from the mold cavity when the casting has solidified to a temperature which is below the solidus temperature of the alloy and yet lies within less than 200 C below solidus temperature.

7. A centrifugal casting apparatus for casting metal products comprising, an isotropic graphite mold having a cavity, and means for rotating the isotropic graphite mold, wherein a coating of either hafnium carbide or tungsten or rhenium is deposited on the surface of the cavity.