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CN107745093B - Fine casting module and casting method for preparing nickel-based single crystal guide vane with precisely controllable crystal orientation by utilizing fine casting module - Google Patents

Fine casting module and casting method for preparing nickel-based single crystal guide vane with precisely controllable crystal orientation by utilizing fine casting module Download PDF

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Publication number
CN107745093B
CN107745093B CN201711272852.6A CN201711272852A CN107745093B CN 107745093 B CN107745093 B CN 107745093B CN 201711272852 A CN201711272852 A CN 201711272852A CN 107745093 B CN107745093 B CN 107745093B
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casting
crystal
wax
seed crystal
pouring
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CN107745093A (en
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杜应流
葛丙明
施长坤
冯文刚
汪兴芳
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Anhui Yingliu Hangyuan Power Technology Co Ltd
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Anhui Yingliu Hangyuan Power Technology Co Ltd
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22CFOUNDRY MOULDING
    • B22C9/00Moulds or cores; Moulding processes
    • B22C9/22Moulds for peculiarly-shaped castings
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22CFOUNDRY MOULDING
    • B22C9/00Moulds or cores; Moulding processes
    • B22C9/02Sand moulds or like moulds for shaped castings
    • B22C9/04Use of lost patterns
    • CCHEMISTRY; METALLURGY
    • C30CRYSTAL GROWTH
    • C30BSINGLE-CRYSTAL GROWTH; UNIDIRECTIONAL SOLIDIFICATION OF EUTECTIC MATERIAL OR UNIDIRECTIONAL DEMIXING OF EUTECTOID MATERIAL; REFINING BY ZONE-MELTING OF MATERIAL; PRODUCTION OF A HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; SINGLE CRYSTALS OR HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; AFTER-TREATMENT OF SINGLE CRYSTALS OR A HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; APPARATUS THEREFOR
    • C30B11/00Single-crystal growth by normal freezing or freezing under temperature gradient, e.g. Bridgman-Stockbarger method
    • C30B11/14Single-crystal growth by normal freezing or freezing under temperature gradient, e.g. Bridgman-Stockbarger method characterised by the seed, e.g. its crystallographic orientation
    • CCHEMISTRY; METALLURGY
    • C30CRYSTAL GROWTH
    • C30BSINGLE-CRYSTAL GROWTH; UNIDIRECTIONAL SOLIDIFICATION OF EUTECTIC MATERIAL OR UNIDIRECTIONAL DEMIXING OF EUTECTOID MATERIAL; REFINING BY ZONE-MELTING OF MATERIAL; PRODUCTION OF A HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; SINGLE CRYSTALS OR HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; AFTER-TREATMENT OF SINGLE CRYSTALS OR A HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; APPARATUS THEREFOR
    • C30B29/00Single crystals or homogeneous polycrystalline material with defined structure characterised by the material or by their shape
    • C30B29/10Inorganic compounds or compositions
    • C30B29/52Alloys

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Crystallography & Structural Chemistry (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Mechanical Engineering (AREA)
  • Inorganic Chemistry (AREA)
  • Crystals, And After-Treatments Of Crystals (AREA)

Abstract

The invention discloses a precise casting method adopting a specific tree structure combined with a seed crystal method and a seeding method, wherein the nickel-based single crystal superalloy guide vane prepared by the method can precisely control crystal orientation and obtain high grain integrity. Firstly, detecting the crystal orientation of a nickel-based single crystal superalloy test block by using a Laol method, and preparing a single crystal seed block with required crystal orientation by using a wire cutting machine or other similar methods; then, according to the tree assembly method disclosed by the invention, a pouring cup, a pouring system, a casting wax mould, a bottom plate and the like are combined from top to bottom to prepare a wax mould module; coating ceramic refractory slurry on the outer surface of the module to form a ceramic mould shell; the casting is prepared through dewaxing, roasting, seed crystal installation and casting processes. The method provided by the invention can accurately control the crystal orientation to be within 5 degrees and improve the crystal grain integrity of castings, thereby improving the performance and casting qualification rate of single crystal guide vanes.

Description

Fine casting module and casting method for preparing nickel-based single crystal guide vane with precisely controllable crystal orientation by utilizing fine casting module
Technical Field
The invention mainly relates to the field of precision casting, in particular to a method for precisely casting a nickel-based single crystal superalloy guide blade (a single crystal guide blade for short in the invention) with precisely controlled crystal orientation.
Background
With the continuous improvement of the thrust-weight ratio and the working efficiency requirements of the aero-engine, the front temperature of the turbine of the aero-engine is also continuously improved, and even reaches the high temperature above 1550 ℃. The common equiaxed grain structure superalloy blade is difficult to service under the working condition. Single crystal superalloys are increasingly used because of their high melting point, high temperature strength, excellent creep resistance, and the like. But is notable for: 1. single crystal parts have significant anisotropy, with best performance when their <001> orientation is parallel to the in-service stressed direction. Therefore, the included angle between the stressed direction of the casting and the <001> direction of the casting is generally required to be not more than 15 degrees and even 10 degrees, otherwise, the casting is judged to be scrapped; 2. in addition, the grain boundary strengthening elements are removed from the single crystal superalloy, so that once grain boundaries exist in the casting, the integrity of grains is destroyed, and the performance is greatly reduced. Thus, acceptable single crystal blades must have good grain integrity and acceptable crystal orientation.
However, due to the special geometry of the guide vane, the cross-sectional dimension in the stacking axis direction is suddenly increased from bottom to top, then suddenly decreased, and then suddenly increased again and decreased again. According to the solidification principle, casting of this type into a single crystal structure with controllable grain orientation is almost impossible according to conventional methods. This also limits the development of our country aero-engine to a great extent.
The casting method of the monocrystal superalloy provided by the invention can effectively solve the problem, and a casting with the crystal grain integrity and the crystal orientation meeting the requirements is prepared.
Disclosure of Invention
The invention aims to provide a casting method for obtaining a single crystal guide vane with good grain integrity and precisely controlled crystal orientation.
In order to realize the scheme, the technical solution of the invention comprises the following steps:
the fine casting mould group comprises a subgroup tree structure, a pouring system and a pouring cup, wherein the subgroup tree structure, the pouring system and the pouring cup are arranged on a bottom plate, the pouring cup is arranged on the upper part of the pouring system, the subgroup tree structure comprises guide blades and a grain generator, the guide blades are provided with fan-shaped arc segment structures, and each guide blade comprises a blade body, an inner arc shroud, an outer arc shroud and a lacing wire boss (A, B, C, D); the grain generator comprises a crystallization section, and the crystallization section is connected with the lower end face of the blade body.
In order to ensure the crystal grain integrity of the single crystal, the single crystal guide vane can be cast in a mode shown in fig. 2, so that the trend that the cross section size of the casting gradually increases from bottom to top is approximately formed, the size of a solidification interface is prevented from being suddenly increased, the supercooling degree of a partial region is suddenly increased, new crystal nuclei are formed and grow up rapidly, the crystal grain integrity of the single crystal casting of the casting is damaged, and the single crystal is scrapped. If unavoidable sudden increase of the cross section size or occurrence of a reverse hanging part occurs, a seeding strip is used for preventing and controlling miscellaneous crystals, and the seeding strip is positioned in a space formed among an inner arc shroud, an outer arc shroud and a lacing wire boss (A, B, C, D) of the guide vane.
The lacing wire bosses (A, B, C, D) are radially distributed.
A casting method for preparing nickel-based single crystal guide vanes with controllable crystal orientation by utilizing the precision casting mould group comprises the following steps:
(2) Preparation of nickel-base superalloy seed crystal
Detecting the orientation of the monocrystal superalloy by combining with a Laue method, directionally cutting out a seed crystal meeting the requirements on a nickel-based monocrystal superalloy block, wherein the <001> direction of the seed crystal is parallel to the normal direction of the inclined plane at the top of the seed crystal, and polishing, polishing and cleaning the surface of the nickel-based superalloy seed crystal; ensuring that the surface of the seed crystal has no redundant adhesion, greasy dirt, oxide skin and the like;
(2) Wax pressing
Injecting the wax material into corresponding wax mould under the conditions of 40-120 ℃ and 0.5-20Mpa injection pressure to obtain a subgroup tree structure wax mould, a pouring cup wax mould, a bottom plate wax mould and a pouring system wax mould; combining the subgroup tree structure wax pattern, the pouring cup wax pattern and the pouring system wax pattern with the bottom plate wax pattern to obtain a wax pattern module;
(4) Preparation of the shuttering
Coating a precision casting mold shell with the thickness of 3-20mm on the surface of a wax mold module, dewaxing at 120-200 ℃, and roasting at 800-950 ℃ for 1-5 hours to obtain the precision casting mold shell for single crystal orientation;
(5) Seed placement
Placing the prepared seed crystal into a seed crystal inner cavity of the grain generator 10, keeping a certain gap with the inner wall of the die shell cavity of the grain generator, and determining the relative position with the inner wall of the die shell cavity by taking the inclined surface of the top of the seed crystal as a reference; the <001> direction is perpendicular to the top inclined plane of the seed crystal, the crystal face (001) is parallel to the top inclined plane, the (001) face is a face formed by four points of the lacing wire boss A, B, C, D, and the <001> direction is the normal direction of the (001) face; then placing the ceramic heat insulation sheet at the corresponding position of the lower part of the seed crystal, and fixing the ceramic heat insulation sheet by glue; the ceramic heat insulating sheet ensures that the seed crystal can be partially remelted; the remelting length of the seed crystal is controlled within the range of 30% -65%, and when the remelting part of the seed crystal is higher or lower than the range, the control of the orientation of the seed crystal is possibly invalid, so that the casting with unqualified crystal orientation is prepared.
(6) Casting
Placing the precision casting mould shell for single crystal orientation into a directional solidification furnace, setting parameters to the mould shell heat preservation temperature of 1400-1600 ℃, remelting and casting a master alloy ingot into the mould shell after the temperature is reached, wherein the casting temperature is 1400-1600 ℃, standing for 10-100 seconds after casting, and carrying out drawing, wherein the drawing speed is set to 1.5-10mm/min. And after the crystal pulling is finished, cooling for 2-30 minutes along with the furnace, taking out, cutting off a pouring system, polishing and grinding to prepare the required single crystal guide vane casting blank.
The gap between the seed crystal and the inner wall of the die shell cavity of the die generator is ensured to be in the range of 0.1mm-0.25 mm. If the gap is too large, the melt is immersed into the gap between the non-remelted seed crystal and the inner wall of the mould shell and is chilled to reform; the gap is too small, which can cause the metal expansion amount to be too large in the heating process and exceed the expansion amount of the ceramic shell, so that stress is generated and even the mould shell is broken, and the flame is caused.
The beneficial effects brought by the invention are as follows:
1. the invention adopts a special tree combination method, combines a seeding strip technology, a directional solidification technology and the like, and the prepared single crystal guide vane has good crystal grain integrity and no crystal grain defects such as large-angle crystal boundaries, mixed crystals, broken crystals, equiaxed crystals and the like.
2. According to the invention, the seed crystal method is adopted to control the orientation of the monocrystalline casting, the prepared monocrystalline guide vane has good crystal orientation, and the included angle between the casting <001> direction and the stacking axis direction required by the casting acceptance specification is smaller than 5 degrees.
3. The method can effectively improve the casting qualification rate and quality of the single crystal guide vane.
Drawings
FIG. 1 is a schematic diagram of a single crystal guide vane precision casting die set structure of the present invention.
FIG. 2 is a schematic diagram of a single crystal guide vane grain integrity and orientation control system of the present invention.
Fig. 3 is a schematic diagram of the <001> crystal orientation and the (001) crystal plane mentioned in the present invention.
Fig. 4 is a schematic illustration of the gap design of the die shell of the seed and grain generator of the present invention.
Detailed Description
As shown in fig. 1, a fine casting module of a nickel-based single crystal guide vane with a precisely controllable crystal orientation comprises a subgroup tree structure 6, a pouring system 7 and a pouring cup 8 which are arranged on a bottom plate 5, wherein the pouring cup 8 is arranged on the upper part of the pouring system 7, the subgroup tree structure 6 comprises two parts of guide blades 9 and a grain generator 10, and the guide blades 9 are provided with fan-shaped arc segment structures and comprise a vane body 1, an inner arc shroud ring 2, an outer arc shroud ring 3 and a lacing wire boss 4; the grain generator 10 comprises a seeding section 13, and the seeding section 13 is connected with the lower end face of the blade body 1.
The seeding strip 14 is positioned in a space formed among the inner arc shroud 2, the outer arc shroud 3 and the lacing wire boss 4 of the guide vane 9.
The lacing wire boss 4 is radially distributed.
The guide vane is generally in a fan-shaped arc section structure as shown in fig. 1, and four points of the lacing wire boss 4 are radially distributed.
In the wax module combination stage, the seed crystal 11 and the ceramic heat-insulating sheet 12 are all formed by wax elements with the same geometric shape and a certain shrinkage rate, and after the preparation of the mould shell is completed, the seed crystal 11 and the ceramic heat-insulating sheet 12 are positioned in the mould shell cavity through corresponding references before the casting procedure is carried out.
In order to ensure the crystal grain integrity of the single crystal, the single crystal guide vane can generally form a trend that the cross section size of the casting gradually increases from bottom to top so as to prevent the size of a solidification interface from suddenly increasing, the supercooling degree of a partial region is suddenly increased, new crystal nuclei are formed and rapidly grow up, and the crystal grain integrity of the single crystal casting of the casting is damaged, so that the single crystal is scrapped. If an unavoidable cross-sectional dimension bump or a flip-flop occurs, the seeding strip 14 is used to prevent and treat the impurity crystals.
A casting method for preparing nickel-based single crystal guide vanes with precisely controllable crystal orientation by a precision casting mould group comprises the following steps:
(1) Preparation of nickel-base superalloy seed crystal
Detecting the orientation of the monocrystal superalloy by combining with a Laue method, directionally cutting out a seed crystal 11 meeting the requirements on a nickel-based monocrystal superalloy block, wherein the <001> direction of the seed crystal is parallel to the normal direction of an inclined plane 16 at the top of the seed crystal 11, and grinding, polishing and cleaning the surface of the nickel-based superalloy seed crystal; ensuring that the surface of the seed crystal 11 is free from redundant adherents, greasy dirt, oxide skin and the like;
(2) Wax pressing
Injecting the wax material into corresponding wax mould under the conditions of 40-120 ℃ and 0.5-20Mpa injection pressure to obtain a subgroup tree structure wax mould, a pouring cup wax mould, a bottom plate wax mould and a pouring system wax mould; combining the subgroup tree structure wax pattern, the pouring cup wax pattern and the pouring system wax pattern with the bottom plate wax pattern to obtain a wax pattern module;
(4) Preparation of the shuttering
Coating a precision casting mold shell with the thickness of 3-20mm on the surface of a wax mold module, dewaxing at 120-200 ℃, and roasting at 800-950 ℃ for 1-5 hours to obtain the precision casting mold shell for single crystal orientation;
(5) Seed placement
Placing the prepared seed crystal 11 into a seed crystal inner cavity of the grain generator 10, keeping a certain gap 15 with the inner wall of the mould cavity of the grain generator 10, and determining the relative position with the inner wall of the mould cavity by taking a seed crystal top inclined plane 16 as a reference; the <001> direction is perpendicular to the seed crystal top inclined plane 16, the crystal face (001) is parallel to the top inclined plane 16, the (001) face is a face formed by four points of the lacing wire boss 4 (A, B, C, D), and the <001> direction is the normal direction of the (001) face; then placing the ceramic heat insulation sheet 12 at the corresponding position of the lower part of the seed crystal 11, and fixing the ceramic heat insulation sheet by glue; the ceramic insulating sheet 12 ensures that the seed crystal can be partially remelted; the remelting length of the seed crystal 11 is controlled within the range of 30% -65%, and the remelting part of the seed crystal 11 is higher or lower than the range, so that the control of the orientation of the seed crystal 11 is possibly invalid, and a casting with unqualified crystal orientation is prepared;
(6) Casting
Placing the precision casting mould shell for single crystal orientation into a directional solidification furnace, setting parameters to the mould shell heat preservation temperature of 1400-1600 ℃, remelting and casting a master alloy ingot into the mould shell after the temperature is reached, wherein the casting temperature is 1400-1600 ℃, standing for 10-100 seconds after casting, and carrying out drawing, wherein the drawing speed is set to 1.5-10mm/min. And after the crystal pulling is finished, cooling for 2-30 minutes along with the furnace, taking out, cutting off a pouring system, polishing and grinding to prepare the required single crystal guide vane casting blank.
The gap 15 between the seed crystal 11 and the inner wall of the die cavity of the die shell of the grain generator 10 is ensured to be in the range of 0.1mm-0.25 mm. If the gap 15 is too large, the melt is immersed into the gap between the non-remelted seed crystal and the inner wall of the mould shell and is chilled to reform; the gap is too small, which can cause the metal expansion amount to be too large in the heating process and exceed the expansion amount of the ceramic shell, so that stress is generated and even the mould shell is broken, and the flame is caused.

Claims (1)

1. A casting method for preparing nickel-based single crystal guide vanes with precisely controllable crystal orientation by utilizing a precision casting mould group is characterized in that:
the precision casting mould group comprises a subgroup tree structure, a pouring system and a pouring cup, wherein the subgroup tree structure, the pouring system and the pouring cup are arranged on the bottom plate, the pouring cup is arranged on the upper part of the pouring system, the subgroup tree structure comprises guide blades and a grain generator, and the guide blades are provided with fan-shaped arc segment structures and comprise blade bodies, inner arc shroud bands, outer arc shroud bands and lacing wire bosses; the grain generator comprises a crystallization section, and the crystallization section is connected with the lower end face of the blade body;
the fine casting module further comprises seeding strips for preventing and controlling mixed crystals, the seeding strips are positioned in a space formed among the inner arc shroud ring, the outer arc shroud ring and the lacing wire boss of the guide vane, and the lacing wire boss is radially distributed;
the casting method comprises the following steps:
(1) Preparation of nickel-base superalloy seed crystal
Detecting the orientation of the monocrystal superalloy by combining with a Laue method, directionally cutting out a seed crystal meeting the requirements on a nickel-based monocrystal superalloy block, wherein the <001> direction of the seed crystal is parallel to the normal direction of the inclined plane at the top of the seed crystal, and polishing, polishing and cleaning the surface of the nickel-based superalloy seed crystal;
(2) Wax pressing
Injecting the wax material into corresponding wax mould under the conditions of 40-120 ℃ and 0.5-20Mpa injection pressure to obtain a subgroup tree structure wax mould, a pouring cup wax mould, a bottom plate wax mould and a pouring system wax mould; combining the subgroup tree structure wax pattern, the pouring cup wax pattern and the pouring system wax pattern with the bottom plate wax pattern to obtain a wax pattern module;
(3) Preparation of the shuttering
Coating a precision casting mold shell with the thickness of 3-20mm on the surface of a wax mold module, dewaxing at 120-200 ℃, and roasting at 800-950 ℃ for 1-5 hours to obtain the precision casting mold shell for single crystal orientation;
(4) Seed placement
Placing the prepared seed crystal into a seed crystal inner cavity of the grain generator 10, keeping a gap of 0.1mm-0.25mm with the inner wall of the die shell cavity of the grain generator, and determining the relative position with the inner wall of the die shell cavity by taking the inclined surface of the top of the seed crystal as a reference; the <001> direction is perpendicular to the top inclined plane of the seed crystal, the crystal face (001) is parallel to the top inclined plane, the (001) face is a face formed by four points of the lacing wire boss A, B, C, D, and the <001> direction is the normal direction of the (001) face; then placing the ceramic heat insulation sheet at the corresponding position of the lower part of the seed crystal, and fixing the ceramic heat insulation sheet by glue;
(5) Casting
Placing the precision casting mould shell for single crystal orientation into a directional solidification furnace, setting parameters to the mould shell heat preservation temperature of 1400-1600 ℃, remelting and pouring a master alloy ingot into the mould shell after the temperature is reached, wherein the pouring temperature is 1400-1600 ℃, standing for 10-100s after pouring, and then carrying out drawing, wherein the drawing speed is set to 1.5-10mm/min; and after the crystal pulling is finished, cooling for 2-30min along with the furnace, taking out, cutting off a pouring system, polishing and grinding to prepare the required single crystal guide vane casting blank.
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