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EP0575685A1 - Investment casting with wear surfaces - Google Patents

Investment casting with wear surfaces Download PDF

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Publication number
EP0575685A1
EP0575685A1 EP92810477A EP92810477A EP0575685A1 EP 0575685 A1 EP0575685 A1 EP 0575685A1 EP 92810477 A EP92810477 A EP 92810477A EP 92810477 A EP92810477 A EP 92810477A EP 0575685 A1 EP0575685 A1 EP 0575685A1
Authority
EP
European Patent Office
Prior art keywords
ceramic
embedded
casting
casting according
porous ceramic
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
Application number
EP92810477A
Other languages
German (de)
French (fr)
Other versions
EP0575685B1 (en
Inventor
Fritz Staub
John Antony Dr. Peters
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Sulzer Markets and Technology AG
Original Assignee
Sulzer Innotec AG
Sulzer AG
Gebrueder Sulzer AG
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Sulzer Innotec AG, Sulzer AG, Gebrueder Sulzer AG filed Critical Sulzer Innotec AG
Priority to DE59207902T priority Critical patent/DE59207902D1/en
Priority to EP92810477A priority patent/EP0575685B1/en
Priority to AT92810477T priority patent/ATE147669T1/en
Priority to JP5149583A priority patent/JPH06170514A/en
Publication of EP0575685A1 publication Critical patent/EP0575685A1/en
Application granted granted Critical
Publication of EP0575685B1 publication Critical patent/EP0575685B1/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
    • F01D5/12—Blades
    • F01D5/14—Form or construction
    • F01D5/20—Specially-shaped blade tips to seal space between tips and stator
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D19/00—Casting in, on, or around objects which form part of the product
    • B22D19/0054—Casting in, on, or around objects which form part of the product rotors, stators for electrical motors
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D19/00—Casting in, on, or around objects which form part of the product
    • B22D19/08—Casting in, on, or around objects which form part of the product for building-up linings or coverings, e.g. of anti-frictional metal
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D19/00—Casting in, on, or around objects which form part of the product
    • B22D19/14—Casting in, on, or around objects which form part of the product the objects being filamentary or particulate in form
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C1/00—Making non-ferrous alloys
    • C22C1/10—Alloys containing non-metals
    • C22C1/1036—Alloys containing non-metals starting from a melt

Definitions

  • the invention relates to a method for producing castings with ceramic embedded in composite form, and to castings which are produced by means of such a method.
  • first phase being formed by a base material and a second phase — in a special spatial arrangement — being embedded in the first phase.
  • the base material is often metallic (pure metal or alloy) and the deposits are made of ceramic material.
  • dispersion alloys dispersion-hardened materials
  • the first phase serves as a binder for the ceramic particles of the second phase, which, in terms of volume, makes up the main part of the composite.
  • Cermets are manufactured using powder metallurgy. They are suitable as wear-resistant materials.
  • the ceramic reinforcement of the cast must be provided in the webs, in the area that is worn away by the wear processes.
  • the ceramic inclusions have a macroscopic character in the castings according to the invention.
  • the casting according to the invention is carried out by means of an investment casting process in which meltable or burnable models are used for the production of the molded shell.
  • meltable or burnable models are used for the production of the molded shell.
  • wax is used for the unreinforced parts of the casting wax with advantage for the model.
  • the porous ceramic bodies intended for the reinforcement are integrated into the cast model, the pore spaces of the ceramic bodies being filled beforehand with wax - or instead of wax with a plastic which volatilizes without residue when the molded shell is fired.
  • the porous ceramic body which has a completely communicating pore space and whose ceramic structure forms a three-dimensional network, can be produced in various ways. Three examples of these manufacturing processes are described below.
  • the following ceramic structures result from these processes: 1. a pile of granular particles; 2. a ceramic structure consisting of rib-like and sintered grain-like particles; 3. a ceramic structure with an open-cell foam structure.
  • the base material used is advantageously a stainless steel, as is customary when casting such plates (ASTM CB-30 or X 35 CrMo 17).
  • Nickel-based or cobalt-based alloys can also be used.
  • the ceramic material must be inert to the melt.
  • aluminum oxide (corundum), zirconium oxide or magnesium oxide can be used; Silicon carbide, on the other hand, is unsuitable because this substance reacts with the melt.
  • a refiner plate 1 with webs 10 is shown in detail in FIG.
  • the web surface 15 (the grinding surface) is subjected to wear during the milling of the fibrous material.
  • the wear areas of the webs 10 consist of a steel / ceramic composite 20, in which a porous ceramic body 2 is embedded in cast steel.
  • the base body 11 of the refiner plate 1 and the web base areas have no embedded ceramic; this maintains the high toughness of the cast material in the web roots, where large bending moments occur during grinding.
  • the cross-sectional drawing in FIG. 2 shows part of the molded shell 30 (including a cast model with a base body 11 'and a wax-filled ceramic body 20').
  • the casting is advantageously carried out in the position shown in order to obtain a good filling of the pore space of the ceramic body 2 by the melt.
  • a ventilation duct 12 see FIG. 3, is provided below the webs 10, the air displacement from the pore spaces improves.
  • the poured channel 12 is, of course, removed during the reworking of the casting.
  • the molded shell 30 is heated before casting to at least a temperature customary for precision casting (around 1150 ° C.).
  • the melt whose liquidus temperature is between around 1300 and 1400 ° C, is overheated. As experience has shown, the pore spaces of the ceramic bodies 2 fill completely thanks to the overheating before the solidification of the melt occurs.
  • FIGS. 4, 5 and 6 relate to the production of a first porous ceramic body 2
  • Ceramic grains 21 for example corundum, diameter between 0.8 and 1.2 mm
  • a pile 2 'with a pore space 22 is formed.
  • This pore space 22 is filled with a free-flowing binder (eg silicate binder) and then emptied again via the outlet 32, bridges 21a of the binder material being formed between the grains.
  • a coherent ceramic body 2 is obtained, which can be removed from the trough 31 and solidified by firing.
  • the ceramic body 2 is filled with wax and installed in the casting model for the production of the molded shell 30.
  • the wax is removed from the surface 23 of the ceramic body 2, so that a direct connection between the grains 21 and the molded shell 30 is created. After the wax 35 has melted out, there is a connection between the ceramic body 2 and the molded shell 30.
  • a surface 23 is formed with the metallic phase 35 filling the pore space 22, from which tips of the grains 21 emerge.
  • a second porous ceramic body 2 is produced by means of an open-cell foam structure 50 made of plastic, see FIG. 7.
  • the two net layers are connected to one another by invisible rungs.
  • the average distance between adjacent ones Mesh layers can be equated to the average cell diameter, the cell diameter is in the range of around 1 to 5 mm 50 applied.
  • the diving and Subsequent sanding must be carried out several times - for example three times.
  • the resulting rib-like agglomerate of ceramic grains is sintered together by firing, the plastic of the original foam structure 50 evaporating at the same time.
  • this ceramic body 2 is again shown as in FIG. 7 with two net layers 25 and 25 '(on an enlarged scale), the ceramic grains being drawn only for the upper net layer 25, however somewhat too large.
  • the third ceramic body 2 shown in FIG. 9 consists of a commercially available ceramic structure which is used, for example, as a filter for molten metal.
  • the production of this ceramic framework with an open-cell foam structure is known for example from CH-PS 679394.
  • FIG. 9 shows a section through the walls of the ceramic foam structure 26. Thanks to openings 27 in the walls, the cells form a completely communicating pore space 22.
  • FIG. 10 shows the ceramic structure 26 of FIG. 9, the pore space of which is filled with the metallic phase 28 (or with wax or plastic) and forms the composite body 20.
  • the metallic phase 28 is washed out on the web surfaces, as indicated in FIG. 11.
  • the relief-like surface structure probably has an improved fibrillating effect when the pulp is ground.
  • FIG. 12 shows a turbine blade tip 100 with armor 102, which is designed as a casting according to the invention.
  • the Armor 102 is formed by a casting zone with embedded ceramic, while the main part 101 of the blade is an unreinforced casting (for example the product of a method with directional solidification).

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • General Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
  • Manufacture Of Alloys Or Alloy Compounds (AREA)
  • Compositions Of Oxide Ceramics (AREA)
  • Dental Prosthetics (AREA)
  • Mold Materials And Core Materials (AREA)

Abstract

The method according to the invention makes it possible to produce castings (1) with ceramics embedded in the manner of composites. In this method, overheated melt is poured into a ceramic moulding shell (30), integrated into the cavity of which is at least one porous ceramic body. Such a ceramic body (2), which has a fully intercommunicating pore volume (22) and the ceramic structure (26) of which forms a three-dimensional network, at least partially fills the cavity of the moulding shell. The porous ceramic body is connected to the wall of the moulding shell. In the case of refiner plates (1) for paper manufacture, the webs (10) can be reinforced in the region (20) of the beating surfaces (15) with embedded ceramic (2). Castings according to the invention can also be used for the production of turbine blades (100) with armoured tips. <IMAGE>

Description

Die Erfindung bezieht sich auf ein Verfahren zum Herstellen von Gussstücken mit verbundartig eingelagerter Keramik sowie auf Gussstücke, die mittels eines derartigen Verfahrens hergestellt sind.The invention relates to a method for producing castings with ceramic embedded in composite form, and to castings which are produced by means of such a method.

Bei Verbundwerkstoffen sind verschiedene Arten von Stoffgruppen zusammengefügt, wobei in vielen Fällen eine erste Phase durch einen Basiswerkstoff gebildet wird und eine zweiten Phase - in einer besonderen räumlichen Anordnung - in die erste Phase eingelagert ist. Oft ist der Basiswerkstoff metallisch (Reinmetall oder Legierung) und die Einlagerungen bestehen aus keramischem Material. Bei Dispersionslegierungen (dispersionsgehärteten Werkstoffen) sind harte Teilchen - gebildet beispielsweise durch Oxide, Karbide, Boride oder Nitride - in feindispersiver Form in die metallische erste Phase eingelagert. Bei einer anderen Art von Teilchenverbundwerkstoffen, nämlich den sogenannten Cermets (ceramics/metals), dient die erste Phase als Bindemittel für die keramischen Teilchen der zweiten Phase, welche volumenbezogen den Hauptteil des Verbundwerkstoffes ausmacht. Cermets werden pulvermetallurgisch hergestellt. Sie eignen sich als verschleissfeste Werkstoffe.In the case of composite materials, different types of material groups are put together, in many cases a first phase being formed by a base material and a second phase — in a special spatial arrangement — being embedded in the first phase. The base material is often metallic (pure metal or alloy) and the deposits are made of ceramic material. In the case of dispersion alloys (dispersion-hardened materials), hard particles - formed, for example, by oxides, carbides, borides or nitrides - are embedded in the metallic first phase in a finely dispersive form. In another type of particle composite, namely the so-called cermets (ceramics / metals), the first phase serves as a binder for the ceramic particles of the second phase, which, in terms of volume, makes up the main part of the composite. Cermets are manufactured using powder metallurgy. They are suitable as wear-resistant materials.

Bei verschiedenen mechanischen Verfahren werden Vorrichtungskomponenten, die als Gussstücke hergestellt sind, starkem Verschleiss unterworfen. Solche Gussstücke trifft man beispielsweise in Refinern bei der Papierherstellung an. In den Refinern wird der im Pulper aufgelöste Faserstoff zwischen Platten mit scharfkantigen Stegen gemahlen, wobei die Fasern zerschnitten und fibrilliert werden. Die Stege der Refinerplatten verlieren beim Mahlvorgang durch Abrasion, Erosion und Korrosion an Höhe und die Kanten werden durch plastische Verformung abgerundet. Um die Verschleissfestigkeit der Refinerplatten zu erhöhen, wird eine Verstärkung der Mahlflächen benötigt: Die Stege sollen - ähnlich wie bei den Cermets oder den Dispersionslegierungen - mittels Keramik verstärkt werden. Um die bei den bekannten Refinern gebene hohe Zähigkeit der Stegbasis zu erhalten, soll die Keramikeinlagerung auf den oberen Bereich der Stege bei den Mahlflächen beschränkt bleiben.In various mechanical processes, device components that are manufactured as castings are subjected to severe wear. Such castings can be found, for example, in refiners used in papermaking. In the refiners, the pulp dissolved in the pulper is ground between plates with sharp-edged webs, the fibers being cut and fibrillated. The ridges of the refiner plates lose height during the grinding process due to abrasion, erosion and corrosion, and the edges are rounded off by plastic deformation. In order to increase the wear resistance of the refiner plates, a reinforcement of the grinding surfaces is required: Similar to the cermets or the dispersion alloys, the webs should be reinforced with ceramics. In order to maintain the high toughness of the bar base given in the known refiners, the ceramic incorporation should be limited to the upper area of the bars at the grinding surfaces.

Es ist Aufgabe der Erfindung, ein Verfahren zur Herstellung von Gussstücken zu schaffen, bei dem das Gussstück zumindest teilweise durch verbundartig eingelagerte Keramik verstärkt wird. Diese Aufgabe wird durch die Merkmale des ersten Anspruchs gelöst. Beim Beispiel der Refinerplatten muss in den Stegen und zwar im Bereich, der durch die Verschleissvorgänge abgetragen wird, für die keramische Verstärkung des Gusses gesorgt werden. Anders als bei den Cermets und Dispersionslegierungen, wo die keramische Phase innerhalb der metallischen Phase mikroskopisch verteilt ist, weisen bei den erfindungsgemässen Gussstücken die keramischen Einlagerungen einen makroskopischen Charakter auf.It is an object of the invention to provide a method for producing castings, in which the casting is at least partially reinforced by ceramic embedded in a composite. This object is achieved by the features of the first claim. In the example of the refiner plates, the ceramic reinforcement of the cast must be provided in the webs, in the area that is worn away by the wear processes. In contrast to the cermets and dispersion alloys, where the ceramic phase is microscopically distributed within the metallic phase, the ceramic inclusions have a macroscopic character in the castings according to the invention.

Der erfindungsgemässe Guss wird mittels eines Feingussverfahrens ausgeführt, bei dem ausschmelzbare oder ausbrennbare Modelle für die Herstellung der Formschale benutzt werden. Für die unverstärkten Teile des Gussstücks wird für das Modell mit Vorteil Wachs verwendet. In das Gussmodell werden die für die Verstärkung vorgesehenen porösen Keramikkörper integriert, wobei die Porenräume der Keramikkörper zuvor mit Wachs gefüllt werden - oder statt Wachs mit einem Kunststoff, der sich beim Brennen der Formschale rückstandfrei verflüchtigt.The casting according to the invention is carried out by means of an investment casting process in which meltable or burnable models are used for the production of the molded shell. For the unreinforced parts of the casting wax is used with advantage for the model. The porous ceramic bodies intended for the reinforcement are integrated into the cast model, the pore spaces of the ceramic bodies being filled beforehand with wax - or instead of wax with a plastic which volatilizes without residue when the molded shell is fired.

Der poröse Keramikkörper, der einen vollständig kommunizierenden Porenraum aufweist und dessen Keramikstrukur ein dreidimensionales Netz bildet, kann auf verschiedene Weisen hergestellt werden. Drei Beispiele für diese Herstellverfahren werden weiter unten beschrieben. Es ergeben sich bei diesen Verfahren folgende Keramikstrukturen: 1. ein Haufwerk von kornartigen Partikeln; 2. eine Keramikstrukur aus gerippeartig angeordneten und zusammengesinterten kornartigen Partikeln; 3. ein keramisches Gerippe mit offenzelliger Schaumstruktur.The porous ceramic body, which has a completely communicating pore space and whose ceramic structure forms a three-dimensional network, can be produced in various ways. Three examples of these manufacturing processes are described below. The following ceramic structures result from these processes: 1. a pile of granular particles; 2. a ceramic structure consisting of rib-like and sintered grain-like particles; 3. a ceramic structure with an open-cell foam structure.

Bei der Herstellung von Refinerplatten nimmt man als Basiswerkstoff mit Vorteil einen rostfreien Stahl, wie er beim Giessen solcher Platten üblich ist (ASTM CB-30 oder X 35 CrMo 17). Auch Nickelbasis- oder Kobaltbasis-Legierungen sind verwendbar. Das keramische Material muss sich gegenüber der Schmelze inert verhalten. Beim Stahlguss kommt beispielsweise Aluminiumoxid (Korund), Zirkonoxid oder Magnesiumoxid in Frage; Siliziumcarbid hingegen ist ungeeignet, da dieser Stoff mit der Schmelze reagiert.When manufacturing refiner plates, the base material used is advantageously a stainless steel, as is customary when casting such plates (ASTM CB-30 or X 35 CrMo 17). Nickel-based or cobalt-based alloys can also be used. The ceramic material must be inert to the melt. For steel castings, for example, aluminum oxide (corundum), zirconium oxide or magnesium oxide can be used; Silicon carbide, on the other hand, is unsuitable because this substance reacts with the melt.

Da die Wärmeausdehung bei Keramik und Stahl verschieden ist, bestanden Bedenken gegenüber der Herstellung des erfindungsgemässen Verbundwerkstoffes. Die Versuche, die entgegen diesen Bedenken ausgeführt wurden, zeigten jedoch, dass die verwendeten Keramikstrukturen im Verbund mit Gussstahl intakt - zumindest ohne störende Schäden - blieben.Since the thermal expansion of ceramic and steel is different, there were concerns about the production of the composite material according to the invention. The tests that were carried out against these concerns, however, showed that the ceramic structures used in combination with cast steel remained intact - at least without any disturbing damage.

Das erfindungsgemässe Verfahren kann auch bei der Herstellung von beispielsweise Lagerteilen oder Dichtungen angewendet werden. In der vorliegenden Beschreibung wird auf die Erfindung hauptsächlich im Zusammenhang mit der erwähnten Refinerplatten eingegangen. Nachfolgend wird die Erfindung anhand der Zeichnungen im Detail erläutert. Es zeigen:

Fig. 1
einen Ausschnitt aus einer Refinerplatte, die nach dem erfindungsgemässen Verfahren hergestellt ist,
Fig. 2
einen Ausschnitt aus der Formschale und dem Modell für den Guss der Refinerplatte gemäss Fig.1,
Fig. 3
eine Variante zur Formschale der Fig.2,
Fig. 4
ein Hilfsmittel für die Herstellung eines ersten porösen Körpers,
Fig. 5
ein Haufwerk von keramischen Körnern,
Fig. 6
das in Gussstahl eingelagerte Haufwerk der Fig.5,
Fig. 7
eine offenzellige Schaumstruktur,
Fig. 8
eine Keramikstrukur aus gerippeartig angeordneten und zusammengesinterten kornartigen Partikeln,
Fig. 9
ein keramisches Gerippe mit offenzelliger Schaumstruktur
Fig. 10
einen Ausschnitt eines Gussstücks mit eingelagerter Keramikstruktur gemäss Fig.9,
Fig. 11
das gleiche Gussstück wie in Fig.10 nach teilweiser Erosion der Oberfläche und
Fig. 12
eine Turbinenschaufelspitze mit Panzerung.
The method according to the invention can also be used in the production of, for example, bearing parts or seals. In the present description, the invention is mainly dealt with in connection with the refiner plates mentioned. The invention is explained in detail below with reference to the drawings. Show it:
Fig. 1
a section of a refiner plate which is produced by the method according to the invention,
Fig. 2
a section of the molded shell and the model for the casting of the refiner plate according to FIG. 1,
Fig. 3
a variant of the molded shell of Figure 2,
Fig. 4
an aid for the production of a first porous body,
Fig. 5
a pile of ceramic grains,
Fig. 6
the pile of cast iron stored in Fig. 5,
Fig. 7
an open-cell foam structure,
Fig. 8
a ceramic structure made up of rib-like and sintered grain-like particles,
Fig. 9
a ceramic structure with an open-cell foam structure
Fig. 10
a section of a casting with embedded ceramic structure according to Figure 9,
Fig. 11
the same casting as in Fig.10 after partial erosion of the surface and
Fig. 12
a turbine blade tip with armor.

In Fig.1 ist ausschnittsweise eine Refinerplatte 1 mit Stegen 10 dargestellt. Die Stegoberfläche 15 (die Mahlfläche) wird beim Mahlen des Faserstoffs dem Verschleiss unterworfen. Die Verschleissbereiche der Stege 10 bestehen erfindungsgemäss aus einem Stahl/Keramik-Verbund 20, in welchem ein poröser Keramikkörper 2 in gegossenem Stahl eingelagert ist. Der Grundkörper 11 der Refinerplatte 1 sowie die Stegbasisbereiche weisen keine eingelagerte Keramik auf; dadurch bleibt die hohe Zähigkeit des Gusswerkstoffs in den Stegwurzeln, wo grosse Biegemomente während des Mahlens auftreten, erhalten.A refiner plate 1 with webs 10 is shown in detail in FIG. The web surface 15 (the grinding surface) is subjected to wear during the milling of the fibrous material. According to the invention, the wear areas of the webs 10 consist of a steel / ceramic composite 20, in which a porous ceramic body 2 is embedded in cast steel. The base body 11 of the refiner plate 1 and the web base areas have no embedded ceramic; this maintains the high toughness of the cast material in the web roots, where large bending moments occur during grinding.

Die Querschnittszeichnung in Fig.2 zeigt einen Teil der Formschale 30 (einschliesslich Gussmodell mit Grundkörper 11' und wachsgefülltem Keramikkörper 20'). Der Guss erfolgt mit Vorteil in der gezeigten Lage, um eine gute Füllung des Porenraums des Keramikkörpers 2 durch die Schmelze zu erhalten. Wird ein Entlüftungskanal 12, siehe Fig.3, jeweils unterhalb der Stege 10 vorgesehen, so verbessert sich die Luftverdrängung aus den Porenräumen. (Der ausgegossene Kanal 12 wird selbstverständlich bei der Überarbeitung des Gussstücks entfernt.) Die Formschale 30 wird vor dem Giessen mindestens auf eine beim Präzisionsguss übliche Temperatur (rund 1150°C) aufgeheizt. Die Schmelze, deren Liquidustemperatur zwischen rund 1300 und 1400°C liegt, wird überhitzt. Wie die Erfahrung gezeigt hat, füllen sich die Porenräume der Keramikkörper 2 dank der Überhitzung vollständig, bevor die Erstarrung der Schmelze eintritt.The cross-sectional drawing in FIG. 2 shows part of the molded shell 30 (including a cast model with a base body 11 'and a wax-filled ceramic body 20'). The casting is advantageously carried out in the position shown in order to obtain a good filling of the pore space of the ceramic body 2 by the melt. If a ventilation duct 12, see FIG. 3, is provided below the webs 10, the air displacement from the pore spaces improves. (The poured channel 12 is, of course, removed during the reworking of the casting.) The molded shell 30 is heated before casting to at least a temperature customary for precision casting (around 1150 ° C.). The melt, whose liquidus temperature is between around 1300 and 1400 ° C, is overheated. As experience has shown, the pore spaces of the ceramic bodies 2 fill completely thanks to the overheating before the solidification of the melt occurs.

Die Figuren 4, 5 und 6 betreffen die Herstellung eines ersten porösen Keramikkörpers 2. In eine Wanne 31 aus Wachs mit einem Ablauf 32 werden Keramikkörner 21 (beispielsweise Korund, Durchmesser zwischen 0,8 und 1,2 mm) eingeschüttet. Es bildet sich dabei ein Haufwerk 2' mit einem Porenraum 22. Dieser Porenraum 22 wird mit einem gut fliessfähigen Bindemittel (z.B. Silikatbinder) gefüllt und anschliessend über den Ablauf 32 wieder entleert, wobei zwischen den Körnern sich Brücken 21a aus dem Bindermaterial ausbilden. Durch Trocknen des Binders erhält man einen zusammenhängenden Keramikkörper 2, den man aus der Wanne 31 entfernen und mittels Brennens verfestigen kann.FIGS. 4, 5 and 6 relate to the production of a first porous ceramic body 2 Ceramic grains 21 (for example corundum, diameter between 0.8 and 1.2 mm) are poured in with a drain 32. A pile 2 'with a pore space 22 is formed. This pore space 22 is filled with a free-flowing binder (eg silicate binder) and then emptied again via the outlet 32, bridges 21a of the binder material being formed between the grains. By drying the binder, a coherent ceramic body 2 is obtained, which can be removed from the trough 31 and solidified by firing.

Der Keramikkörper 2 wird mit Wachs gefüllt und in das Gussmodell für die Herstellung der Formschale 30 eingebaut. An der Oberfläche 23 des Keramikkörpers 2 wird das Wachs entfernt, sodass eine unmittelbare Verbindung zwischen den Körnern 21 und der Formschale 30 entsteht. Nach dem Ausschmelzen des Wachses 35 liegt somit eine Verbindung zwischen dem Keramikkörper 2 und der Formschale 30 vor. Beim Giessen bildet sich mit der den Porenraum 22 füllenden metallischen Phase 35 eine Oberfläche 23 aus, aus welcher Spitzen der Körner 21 hervortreten.The ceramic body 2 is filled with wax and installed in the casting model for the production of the molded shell 30. The wax is removed from the surface 23 of the ceramic body 2, so that a direct connection between the grains 21 and the molded shell 30 is created. After the wax 35 has melted out, there is a connection between the ceramic body 2 and the molded shell 30. During casting, a surface 23 is formed with the metallic phase 35 filling the pore space 22, from which tips of the grains 21 emerge.

Ein zweiter poröser Keramikkörper 2 wird mittels einer offenzelligen Schaumstruktur 50 aus Kunststoff, siehe Fig.7, hergestellt. (Der Übersichtlichkeit halber sind in Fig.7 nur eine Netzlage 55, die an der Oberfläche der Schaumstruktur 50 liegt, und ein zweite, darunter liegende Netzlage 55' dargestellt. Die beiden Netzlagen sind durch nicht sichtbare Sprossen miteinander verbunden. Der mittlere Abstand zwischen benachbarten Netzlagen kann dem mittleren Zelldurchmesser gleichgesetzt werden. Der Zelldurchmesser liegt im Bereich von rund 1 bis 5 mm.) Feine Keramikkörner (beispielsweise Korund, Korndurchmesser 0,06 bis 0,15 mm) werden mittels eines Binders durch Tauchung und Besandung auf die Sprossen der Schaumstrukur 50 aufgebracht. Die Tauchung und anschliessende Besandung muss mehrfach - beispielsweise dreimal - ausgeführt werden. Nachfolgend wird das so erzeugte gerippeartige Agglomerat von Keramikkörnern durch Brennen zusammengesintert, wobei der Kunststoff der ursprünglichen Schaumstruktur 50 sich gleichzeitig verflüchtigt. In Fig.8 ist dieser Keramikkörper 2 wiederum wie in Fig.7 mit zwei Netzlagen 25 und 25' dargestellt (bei vergrössertem Massstab), wobei nur für die obere Netzlage 25 die Keramikkörner - allerdings etwas zu gross - gezeichnet sind.A second porous ceramic body 2 is produced by means of an open-cell foam structure 50 made of plastic, see FIG. 7. (For the sake of clarity, only one net layer 55, which lies on the surface of the foam structure 50, and a second, underneath net layer 55 'are shown in FIG. 7. The two net layers are connected to one another by invisible rungs. The average distance between adjacent ones Mesh layers can be equated to the average cell diameter, the cell diameter is in the range of around 1 to 5 mm 50 applied. The diving and Subsequent sanding must be carried out several times - for example three times. The resulting rib-like agglomerate of ceramic grains is sintered together by firing, the plastic of the original foam structure 50 evaporating at the same time. In FIG. 8, this ceramic body 2 is again shown as in FIG. 7 with two net layers 25 and 25 '(on an enlarged scale), the ceramic grains being drawn only for the upper net layer 25, however somewhat too large.

Der dritte, in Fig.9 gezeigt Keramikkörper 2, besteht aus einer im Handel erhältlichen Keramikstruktur, die beispielsweise als Filter für Metallschmelzen verwendet wird. Die Herstellung dieses keramischen Gerippes mit offenzelliger Schaumstruktur ist beispielsweise aus der CH-PS 679394 bekannt. Fig.9 zeigt einen Schnitt durch die Wandungen der keramischen Schaumstruktur 26. Die Zellen bilden dank Durchbrüchen 27 in den Wandungen einen vollständig kommunizierenden Porenraum 22.The third ceramic body 2 shown in FIG. 9 consists of a commercially available ceramic structure which is used, for example, as a filter for molten metal. The production of this ceramic framework with an open-cell foam structure is known for example from CH-PS 679394. FIG. 9 shows a section through the walls of the ceramic foam structure 26. Thanks to openings 27 in the walls, the cells form a completely communicating pore space 22.

Das Schrägbild in Fig.10 stellt die Keramikstruktur 26 der Fig.9 dar, deren Porenraum mit der metallischen Phase 28 (bzw. mit Wachs oder Kunststoff) gefüllt ist und den Verbundkörper 20 bildet. Bei der Verwendung dieses Verbundkörpers 20 in Refinerplatten ergibt sich wegen der grösseren Widerstandsfähigkeit der Keramik 26 eine Auswaschung der metallischen Phase 28 an den Stegoberflächen, wie es in Fig.11 angedeutet ist. Die reliefartige Oberflächenstruktur weist wahrscheinlich eine verbesserte fibrillierende Wirkung beim Mahlen des Faserstoffs auf.10 shows the ceramic structure 26 of FIG. 9, the pore space of which is filled with the metallic phase 28 (or with wax or plastic) and forms the composite body 20. When this composite body 20 is used in refiner plates, because of the greater resistance of the ceramic 26, the metallic phase 28 is washed out on the web surfaces, as indicated in FIG. 11. The relief-like surface structure probably has an improved fibrillating effect when the pulp is ground.

Bei Schaufeln für Gasturbinen ist es vorteilhaft, wenn deren Spitzen gepanzert werden. Fig. 12 zeigt eine Turbinenschaufelspitze 100 mit einer Panzerung 102, die als erfindungsgemässes Gussstück ausgeführt ist. Die Panzerung 102 wird durch eine Gusszone mit eingelagerter Keramik gebildet, während der Hauptteil 101 der Schaufel ein unverstärkter Gusskörper (beispielsweise das Erzeugnis eines Verfahrens mit gerichteter Erstarrung) ist.In the case of blades for gas turbines, it is advantageous if their tips are armored. 12 shows a turbine blade tip 100 with armor 102, which is designed as a casting according to the invention. The Armor 102 is formed by a casting zone with embedded ceramic, while the main part 101 of the blade is an unreinforced casting (for example the product of a method with directional solidification).

Claims (10)

Verfahren zum Herstellen von Gussstücken (1) mit verbundartig eingelagerter Keramik, durch Giessen einer Schmelze in eine keramische Formschale (30), in deren Hohlraum mindestens ein poröser Keramikkörper integriert ist, wobei ein solcher Keramikkörper (2), der einen vollständig kommunizierenden Porenraum (22) aufweist und dessen Keramikstrukur (26) ein dreidimensionales Netz bildet, zumindest teilweise den Hohlraum der Formschale füllt sowie in Verbindung mit der Wand der Formschale steht, wobei ferner das keramische Material sich gegenüber der Schmelze inert verhält.Method for producing castings (1) with ceramic embedded in a composite manner, by pouring a melt into a ceramic molded shell (30), in the cavity of which at least one porous ceramic body is integrated, such a ceramic body (2) having a completely communicating pore space (22 ) and whose ceramic structure (26) forms a three-dimensional network, at least partially fills the cavity of the molded shell and is in connection with the wall of the molded shell, the ceramic material also being inert to the melt. Verfahren nach Anspruch 1, dadurch gekennzeichnet, dass in das Gussmodell für die Formschale der oder die porösen Keramikkörper integriert werden, wobei der Porenraum des Keramikkörpers jeweils mit Wachs oder einem ausbrennbaren Kunststoff gefüllt ist.Method according to Claim 1, characterized in that the porous ceramic body or bodies are integrated into the casting model for the molded shell, the pore space of the ceramic body being filled with wax or a burn-out plastic. Gussstück (1), in welchem mindestens ein poröser Keramikkörper (2) verbundartig eingelagert ist und welches nach dem Verfahren von Anspruch 1 hergestellt ist.Cast piece (1) in which at least one porous ceramic body (2) is embedded in a composite manner and which is produced by the method of claim 1. Gussstück nach Anspruch 3, dadurch gekennzeichnet, dass die Keramikstrukur von mindestens einem der porösen Keramikkörper (2) ein keramisches Gerippe (26) mit offenzelliger Schaumstruktur bildet, wobei die Zelldurchmesser rund 1 bis 5 mm betragen.Casting according to claim 3, characterized in that the ceramic structure of at least one of the porous ceramic bodies (2) forms a ceramic framework (26) with an open-cell foam structure, the cell diameter being around 1 to 5 mm. Gussstück nach Anspruch 3, dadurch gekennzeichnet, dass die Keramikstrukur von mindestens einem der porösen Keramikkörper (2) in der Form eines Haufwerks von miteinander verbundenen, kornartigen Partikeln (21), deren Durchmesser rund 1mm betragen, vorliegt.Casting according to claim 3, characterized in that the ceramic structure of at least one of the porous ceramic bodies (2) is in the form of a pile of interconnected, grain-like particles (21), the diameter of which is approximately 1 mm. Gussstück nach Anspruch 3, dadurch gekennzeichnet, dass die Keramikstrukur (25, 25') von mindestens einem der porösen Keramikkörper (2) aus gerippeartig angeordneten und zusammengesinterten kornartigen Partikeln, deren Durchmesser rund 0,1mm betragen, aufgebaut ist.Casting according to Claim 3, characterized in that the ceramic structure (25, 25 ') is constructed from at least one of the porous ceramic bodies (2) from rib-like and sintered grain-like particles, the diameter of which is approximately 0.1 mm. Gussstück nach einem der Ansprüche 3 bis 6, dadurch gekennzeichnet, dass die keramische Phase (26) im wesentlichen aus Korund, Zirkonoxid oder Magnesiumoxid und die metallische Phase (28, 35) aus Stahl, einer Nickelbasis- oder Kobaltbasis-Legierung bestehen.Casting according to one of Claims 3 to 6, characterized in that the ceramic phase (26) consists essentially of corundum, zirconium oxide or magnesium oxide and the metallic phase (28, 35) consists of steel, a nickel-based or cobalt-based alloy. Gussstück nach einem der Ansprüche 3 bis 7 und mit Oberflächen (15), die für abrasive Vorgänge vorgesehen sind, dadurch gekennzeichnet, dass die porösen Keramikkörper im Bereich (20) der Verschleissflächen eingelagert sind.Casting according to one of claims 3 to 7 and with surfaces (15) intended for abrasive processes, characterized in that the porous ceramic bodies are embedded in the area (20) of the wear surfaces. Refinerplatte (1) für die Papierherstellung, die als Gussstück gemäss Anspruch 8 gefertigt ist, dadurch gekennzeichnet, dass die Stege (10) im Bereich (20) der Mahlflächen (15) mit eingelagerter Keramik (2) verstärkt sind.Refiner plate (1) for paper manufacture, which is manufactured as a casting according to claim 8, characterized in that the webs (10) in the region (20) of the grinding surfaces (15) are reinforced with embedded ceramic (2). Turbinenschaufel (100) mit gepanzerter Schaufelspitze, die als Gussstück gemäss Anspruch 8 gefertigt ist, dadurch gekennzeichnet, dass die Panzerung (102) durch eine Gusszone mit eingelagerter Keramik gebildet ist.Turbine blade (100) with armored blade tip, which is manufactured as a casting according to claim 8, characterized in that the armor (102) is formed by a casting zone with embedded ceramic.
EP92810477A 1992-06-23 1992-06-23 Investment casting with wear surfaces Expired - Lifetime EP0575685B1 (en)

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AT92810477T ATE147669T1 (en) 1992-06-23 1992-06-23 INVESTMENT CASTING WITH WEAR SURFACES
JP5149583A JPH06170514A (en) 1992-06-23 1993-06-21 Casting with ceramic insertion type composite construction

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ATE147669T1 (en) 1997-02-15
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