DIE CASTING OF HIGH TEMPERATURE MATERIAL

Description

BACKGROUND OF THE INVENTION

[0001] The present invention relates generally to articles fabricated from high melting temperature alloys and/or reactive alloys, and relates more particularly to a method of making such articles by die casting.

[0002] As used herein, the term high melting temperature material is intended to include materials having a melting temperature of at least 2000 °F/ 1093 °C. High melting temperature materials include, for example, titanium and titanium alloys (melting temperature typically above about 3000° F/ 1650 °C), and nickel base and cobalt base superalloys (melting temperatures typically above about 2400° F/ 1315 °C) and iron base superalloys (melting temperatures typically above about 2200° F/ 1200 °C). As used herein, "reactive alloys" include elements that react when exposed to air or other atmosphere which contains oxygen, elements such as titanium, aluminum and iron, and typically react more quickly at elevated temperature.

[0003] Titanium and titanium alloys are employed in applications which require light weight and high strength-weight ratios. These alloys exhibit good corrosion resistance, and generally maintain strength up to relatively high temperatures. e.g., up to at least 1200° F/ 650 °C depending upon the alloy composition. Broadly, the term "titanium alloy" is intended to include alloys composed of at least about 25 at. % titanium.

[0004] In gas turbine engines for example, titanium alloys are employed in the compressor section of the engine, including but not limited to airfoils such as blades and vanes, as well as structural components such as intermediate and compressor cases and compressor disks. One titanium alloy widely utilized in gas turbine engines is Ti 6A1-4V. composition described further below, and is used in environments up to about 600° F/ 315°C. For higher temperature applications, e.g.. in environments up to about 1200° F/650 °C and where improved creep and other high temperature properties are needed. Ti 6Al-2Sn-4Zr-2Mo is employed, composition described further below. Other titanium-base alloys may also be employed, such as Ti 8Al-1Mo-1V. composition also described further below, which exhibits good strength in the range of between about 500 - 1000 °F/ 260 - 538 °C. Titanium aluminides may also be employed, and arc broadly composed of titanium and aluminum in stoichiometric amounts, such as TiAl and TiAl₃.

[0005] Nickel base and cobalt base superalloys are typically employed in the turbine section of gas turbine engines, and in some engines in the latter stages of the compressor section, including blades and vanes as well as components such as intermediate cases and disks, and turbine cases and disks. A typical nickel base superalloy utilized in gas turbine engines is Inconel 718 (IN 718), in broad terms having general a composition in weight percent, of about 0.01 - 0.05 Carbon (C), 13 - 25 Chromium (Cr), 2.5 - 3.5 Molybdenum (Mo). 5.0 - 5.75 (Columbium (Cb) [also referred to as Niobium (Nb)] + Tantalum (Ta)), 0.7 - 1.2 Titanium (Ti), 0.3 - 0.9 Aluminum (Al), up to about 21 Iron (Fe), balance generally Ni. Other alloys are also employed, such as IN 713 and Waspaloy, as disclosed for example in commonly-owned U.S. Pat. Nos. 4,574,015 and 5,120,373 which are expressly incorporated by reference herein, and B-1900. see, e.g., Sims and Hagel, The Superalloys, (Wiley & Sons 1972), pp. 596-7, and cobalt base alloys, such as MAR-M-509, see. e.g., Sims and Hagel.

[0006] IN 939 is another nickel base alloy, useful up to about 1500 F/ 815 °C, and has a nominal composition of about 22.5 Cr, 19 Co, 6 Mo, 2 Al, 3.7 Ti, 2 W, 3.3 (Cb + Ta), 0.1 5 C. 0.005 B, balance generally nickel. IN 939 is difficult if not impossible to forge. Gatorized Waspaloy is an advanced Waspaloy composition developed to provide improved strength and temperature capability over conventional Waspaloy. See, U.S. Pat. Nos. 4,574.015 and 5,120,373. It has a general composition, in weight percent of Chromium 15 .00 - 17 .00. Cobalt 12 .00 - 15 .00, Molybdenum 3 .45 - 4.85, Titanium 4.45 - 4 .75, Aluminum 2 .00 - 2.40 Gator Waspaloy may also small amounts of other elements.

[0007] In addition to the above properties and in order to be used in gas turbine engines, these materials must at least be capable of being formed into relatively complex, three dimensional shapes such as airfoils, and must be oxidation resistant - particularly at elevated temperatures. The above alloys have in the past typically been precision forged to produce parts having a fine average grain size and a balance of high strength, low weight and durability or high cycle fatigue resistance. In the gas turbine engine industry, forging is a preferred method used to produce parts having complex, three-dimensional shapes such as blades and vanes. When properly produced, these parts do exhibit a balance of high strength, low weight, and durability.

[0008] Briefly, in order to forge a part such as an airfoil, an ingot of material is converted into billet form, typically cylindrical for blades and vanes, and is then thermomechanically processed, such as by heating and stamping several times between dies and/or hammers that are shaped progressively similar to the desired shape, in order to plastically deform the material into the desired component shape. The forging dies typically may be heated. Each component is typically heat treated to obtain desired properties, e.g., hardening/strengthening, stress relief, resistance to crack growth and a particular level of HCF resistance, and is also finished, e.g., machined, chem-milled and/or media finished, if necessary to provide the component with the precise shape, dimensions and/or surface features.

[0009] The production of components by forging is an expensive, time consuming process, and thus is typically warranted only for components that require a particular balance of properties, e.g., high strength, low weight and durability, both at room temperature and at elevated temperatures. With respect to obtaining material for forging, certain materials require long lead times. Forging typically includes a series of operation, each requiring separate dies and associated equipment. The post-forging finishing operations, e.g., machining the root portion of a blade and providing the appropriate surface finish, comprise a significant portion of the overall cost of producing forged parts, and include a significant portion of parts which must be discarded.

[0010] During component forging, much of the original material (up to about 85% depending upon the size of the forging) is removed and does not form part of the finished component, e.g., it is process waste. The complexity of the shape of the component produced merely adds to the effort and expense required to fabricate the component, which is an even greater consideration for gas turbine engine components having particularly complex shapes. Some alloys may also exhibit resilient character during forging, which must be taken into account during forging, i.e., the parts must be "over forged". As noted above, finished components may still require extensive post forging processing. Moreover, as computer software is used to apply computational fluid dynamics to analyze and generate more aerodynamically efficient airfoil shapes, such airfoils and components have even more complex three-dimensional shapes. It is more difficult or impossible to forge titanium alloys precisely into these advanced, more complex shapes, which adds further to the cost of the components or renders the components so expensive that it is not economically feasible to exploit certain advances in engine technology, or to utilize particular alloys for some component shapes.

[0011] Forged components may contain forging imperfections that tend to be difficult to inspect. Moreover, precise reproducibility is also a concern - forging does not result in components having dimensions that are precisely the same from part to part. After inspection, many parts must still be re-worked. As a general rule, forged parts must be scrapped or significantly re-worked about 20 % of the time. Moreover, newer, more advanced or more highly alloyed materials will be increasingly difficult (if not impossible) and correspondingly more expensive to forge. These concerns will only intensify as more complex three-dimensional airfoil geometries are employed.

[0012] Casting has been extensively used to produce relatively near-finished-shape articles.

[0013] Investment casting, in which molten metal is poured into a ceramic shell having a cavity in the shape of the article to be cast, can be used to produce such articles. However investment casting produces extremely large grains, e.g., ASTM 0 or larger (relative to the small average grain size achievable by forging), and in some cases the entire part comprises a single grain. Moreover, since an individual mold is produced for each part, this process is expensive. Reproducibility of very precise dimensions from part to part is difficult to achieve. If the material is melted, poured and/or solidified in the presence of a gas, parts may have undesirable properties such as inclusions and porosity, particularly for materials containing reactive elements such as titanium or aluminum. Spallation of the ceramic shell also contributes to the presence of inclusions and impurities.

[0014] Permanent mold casting, in which molten material is poured into a multipart, reusable mold and flows into the mold under only the force of gravity, has also been used to cast parts generally. See, e.g., U.S. Pat. No. 5,505,246 to Colvin. However, permanent mold casting has several drawbacks. For thin castings, such as airfoils, the force of gravity may be insufficient to urge the material into thinner sections, particularly so where high melting temperature materials and low superheats are employed, and accordingly the mold does not consistently fill and the parts must be scrapped. Dimensional tolerances must be relatively large, and require correspondingly more post casting work, and repeatably is difficult to achieve. Permanent mold casting also results in relatively poor surface finish, which also requires significant post cast work.

[0015] Die casting, in which molten metal in injected under pressure into a re-usable die, has been used successfully in the past to form articles from materials having relatively low-melting temperatures, e.g., below about 2000 °F/ 1093 °C. As set forth, for example, in U.S. Pat. Nos. 2,932,865, 3,106,002, 3,532,561 and 3,646,990, a conventional die casting machine includes a shot sleeve mounted to one (typically fixed) platen of a multiple part die, e.g., a two part die including fixed and movable platens which cooperate to define a die cavity. The shot sleeve is oriented horizontally, vertically or inclined between horizontal and vertical. The sleeve typically is constrained at only one end, by the die, e.g., the sleeve is not embedded in a block of material. The sleeve communicates with a runner of the die, and includes an opening on the sleeve through which molten metal is poured. A plunger is positioned for movement in the sleeve, and a driving mechanism moves the plunger and forces molten metal from the sleeve into the die. In a "cold chamber" type die casting machine, the shot sleeve is typically oriented horizontally and is unheated. Casting usually occurs under atmospheric conditions, i.e.. the equipment is not located in a non-reactive environment such as a vacuum chamber or inert atmosphere.

[0016] The drawbacks of such machines are also discussed in U.S. Pat. Nos. 3,646.990 and 3,791,440, both to Cross, particularly in connection with the inability to use such machines to cast higher melting point materials. In conventional machines the atmosphere in the shot sleeve is not evacuated, and the plunger also forces any air from the sleeve into the die resulting in porosity of die cast articles, a condition that is both undesirable and impermissible particularly where the article is to be used in demanding applications such as aerospace components. Accordingly, in order to avoid injecting bubbles with the molten material the shot sleeve must be filled as completely as possible, or is inclined such that any air in the molten material migrates away from the die before injection. Moreover, since the shot sleeve is unheated, a skin or "can" of molten metal solidifies on the inside of the shot sleeve, and in order to move the plunger through the sleeve to inject the molten metal into the die, the plunger must overcome the resistance of the solidified metal, scraping the skin off of the sleeve and thereby "crushing the can". However, the can forms a structurally strong member, e.g., in the form of cylinder which is supported by the sleeve, the plunger and/or associated structure for moving the plunger can be damaged or destroyed due to the resistance to plunger motion. Where the plunger is thermally distorted and fails to match the sleeve shape or the sleeve is thermally distorted altering the clearances between the sleeve and plunger, the passage of metal between plunger and sleeve ("blowback") may occur and/or bind the plunger, all of which detrimentally affects the resultant articles. See also U.S. Pat. No. 3,533,464 to Parlanti et al.

[0017] Despite extensive efforts, the conventional "cold chamber" die casting apparatus have not been used successfully to produce articles composed of high melting temperature materials, such as titanium alloys and superalloys. As used herein, superalloys generally refer to those materials characterized by high strength and which maintain high strength at high temperatures. Such materials are also characterized by relatively high melting points. Past attempts to die cast high melting temperature materials such as titanium alloys and superalloys has resulted in inoperable die casting machinery, as well as articles characterized by inferior qualities such as impurities, excessive porosity, and relatively poor strength and fatigue properties.

[0018] It is an object of the present invention to provide a method of die cast articles composed of high melting temperature materials, e.g., T_m above 2000 °F/ 1093 °C.

[0019] It is another object of the present invention to provide a process of producing die cast titanium alloy articles having properties comparable to corresponding forged articles.

[0020] It is a more specific object of the present invention to provide a method of die casting titanium alloy articles that have strength, durability and fatigue resistance comparable to corresponding forged articles.

[0021] It is also a more specific object of the present invention to provide a method of die casting superalloy articles that have strength, durability and fatigue resistance comparable to corresponding forged titanium articles.

[0022] It is still another object of the present invention to provide such articles having complex, three dimensional shapes that are difficult if not impossible to forge.

[0023] Additional objects will become apparent to those skilled in the art based upon the following disclosure and drawings.

[0024] EP-A-0 901 853 and GB-A-914508 disclose vacuum die casting apparatus and methods.

SUMMARY OF THE INVENTION

[0025] According to one aspect of the invention, a method is disclosed as claimed in claim 1. Resulting articles are characterized by a fine average grain size, for a cast article, and an absence of flowlines. Exemplary high melting temperature alloys include titanium alloys and cobalt base and nickel base superalloys. Exemplary reactive alloys include titanium alloys and iron base superalloys.

[0026] The present invention is advantageous in it obviates the need for forging equipment, and any need to prepare specially tailored billets of material. From the standpoint of required equipment, forging requires the production of multiple dies to make a new part, at significant cost. In contrast, only a single die set is required per part, at significantly reduced expense relative to forging. Accordingly, the time required to produce a part, from ingot to finished part, is reduced significantly. Die casting broadly can be performed in a single operation, as opposed to multiple forging operations. In die casting, multiple parts can be produced in a single casting. Die casting enables the production of parts having more complex, three dimensional shapes than forging, thereby enabling new software design technology to be applied to and exploited in areas such as gas turbine engines and enabling production of more aerodynamically efficient airfoils and other components. Die casting enables the production of such articles utilizing materials that are difficult or impossible to forge. Die cast parts are produced nearer to their finished shape, and with a superior surface finish, thereby minimizing post forming finishing operations, and reducing the cost of producing such parts.

BRIEF DESCRIPTION OF THE DRAWINGS

[0027] 

FIG. is a view of a die cast titanium alloy article in accordance with the present invention.

FIGS. 2 and 3 are schematic views of a die casting machine in accordance with the present invention.

FIG. 4 is a flow diagram illustrating a process of die casting high melting temperature materials in accordance with the present invention.

FIG. 5 is a photomicrograph illustrating the microstructure of an airfoil composed of die cast Ti 6-4 in accordance with the present invention.

FIG. 6 is a photomicrograph illustrating the microstructure of a test bar composed of die cast Ti 6-4 in accordance with the present invention.

FIG. 7 is a photomicrograph illustrating the microstructure of an airfoil composed of forged Ti 6-4.

FIGS. 8 and 9 illustrate a comparison of properties for die cast Ti 6-4 in accordance with the present invention and forged Ti 6-4.

FIGS. 10 and 11 illustrate fatigue properties of die cast Ti 6-4 and corresponding forged articles.

FIG. 12 is a photomicrograph illustrating the microstructure of an airfoil composed of die cast Ti 6-2-4-2 in accordance with the present invention.

FIG. 13 is a photomicrograph illustrating the microstructure of a test bar composed of die cast Ti 6-2-4-2 in accordance with the present invention.

FIG. 14 is a photomicrograph illustrating the microstructure of an airfoil composed of forged Ti 6-2-4-2.

FIG. 15 illustrates a comparison of properties for die cast Ti 6-2-4-2 in accordance with the present invention and forged Ti 6-2-4-2.

FIG. 16 is a photomicrograph illustrating the microstructure of an article composed of die cast Ti 8- 1 - 1.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0028] Turning now to FIG. 1, a die cast article (titanium alloy in the illustrated embodiment) composed of a high melting temperature material in accordance with the present invention is indicated generally by the reference numeral 10. In the illustrated embodiment, the article is a compressor blade 10 for a gas turbine engine, and includes an airfoil 12, a platform 14, and a root 16, but could also be a vane or a structural component for such an engine. The illustrated embodiment is not intended to be limit the present invention to gas turbine engine parts. The term "high melting temperature material" is intended to include materials having a melting temperature of at least 2000 °F/ 1093 °C, and typically over 2500 - 3000° F/ 1370 - 1650 °C. As used herein. "reactive alloys" include elements that react when exposed to air or other atmosphere which contains oxygen, elements such as titanium, aluminum and iron, and typically react more quickly at elevated temperature.

[0029] Articles and processes (FIG. 4) in accordance with the present invention are described in more detail below. We prefer to use a cold chamber type die casting machine (FIGS. 2 - 3) of the type having horizontally oriented, and usually unheated, shot sleeve in accordance with the present invention, since such machines are readily available, and relatively inexpensive and easily repairable if needed. Briefly, at least a single charge of titanium alloy is melted in a manner to minimize contamination. Accordingly, the alloy is heated and melted in a non-reactive, e.g., an inert or preferably vacuum environment. The alloy is also heated to a controlled, limited superheat to ensure that it remains molten until injected into the mold, but not enough to prevent rapid solidification of the molten material after injection. Molten alloy is then transferred to a horizontal shot sleeve of the machine, which is preferably located in a vacuum environment and the molten material is injected under pressure into a reusable mold. The process comprising pouring and injecting the molten material should not exceed a few seconds, with injection occurring preferably in less than one or two seconds, in a die casting machine having an unheated shot sleeve.

[0030] Turning to FIGS. 2, 3 and 4, we prefer to use a die casting machine (FIGS. 2-3) of the type having an unheated shot sleeve ("cold chamber") to produce articles in accordance with the present invention. Generally, a charge of material is prepared (FIG. 4, step 44), and the material to be die cast is melted (step 46 - FIG. 4) in the apparatus 18.. As is generally known, molten titanium is an aggressive material, and attacks the material in which it is melted. Accordingly, we prefer to melt titanium by induction skull remelting or melting (ISR) 24. for example in a unit of the type manufactured by Consarc Corporation of Rancocas, NJ which is capable of rapidly, cleanly melting a single charge of material to be cast, e.g., up to about 25 pounds of material. In ISR, material is melted in a crucible defined a plurality of metal (typically copper) fingers retained in position next to one another. The crucible is surrounded by an induction coil coupled to a power source 26. The fingers include passages for the circulation of cooling water from and to a water source (not shown), to prevent melting of the fingers. The field generated by the coil heats and melts material located in the crucible. The field also serves to agitate or stir the molten metal. A thin layer of the material freezes on the crucible wall and forms the skull, thereby minimizing the ability of molten material to attack the crucible. By properly selecting the crucible and coil, and the power level and frequency applied to the coil, it is possible to urge the molten material away from the crucible, further reducing attack of the crucible wall by the molten material. By melting only a single charge rather than maintaining a large container of molten alloy, we ensure that components having relatively low melting points relative to the alloy as a whole are not vaporized and lost prior to casting.

[0031] Where reactive materials, such as titanium and aluminum and alloys containing these materials, are to be cast it is important to melt the materials in a non-reactive environment, to prevent reaction, contamination or other condition which might detrimentally affect the quality of the resulting articles. Since any gasses in the melting environment may become entrapped in the molten material and result in excess porosity in die cast articles we prefer to melt the material in a vacuum environment rather than in an inert environment, e.g., argon. More preferably the material is melted in a melt chamber 20 coupled to a vacuum source 22 in which the chamber is maintained at a pressure of less than 100 µm, preferably less than 50 µm.

[0032] While we prefer to melt single, or smaller charges of titanium material using an ISR unit, the material may be melted in other manners, such as by vacuum induction melting (VIM) and electron beam melting, so long as the material being melted is not significantly contaminated. Moreover, we do not rule out melting bulk material. e.g., several charges of material at once, in a vacuum environment and then transferring single charges of molten material into the shot sleeve for injection into the die. However, since the material is melted in a vacuum, any equipment used to transfer the molten material must typically be capable of withstanding high temperatures and be positioned in the vacuum chamber, and consequently the chamber must be relatively large. The additional equipment adds cost, and the correspondingly large vacuum chamber takes longer to evacuate thus affecting the cycle time.

[0033] Since some amount of time will necessarily elapse between material melting and injection of the molten material into the die, the material is melted with a limited superheat - high enough to ensure that the material remains at least substantially molten until it is injected, but low enough to ensure that rapid solidification occurs upon injection enabling formation of small grains and also to minimize the thermal load upon the die casting apparatus (particularly those portions of the apparatus which come into contact with the molten metal). The material is sufficiently superheated to ensure that it remains molten until injected into the mold, but the amount of superheat is low enough to enable rapid solidification of the molten material after injection. The controlled superheat is particularly important for superalloys such as IN 718. We have melted titanium alloys and also IN 718 to a controlled, limited superheat. e.g.. we have successfully used superheats within about 100° F to 200° F/ 37 - 95 °C above the melting temperature of the alloy and more preferably within about 50° F to 100° F/ 10 - 37 °C, preferably using a ceramic free melting system such as an inducto-skull melting unit.

[0034] Molten alloy is then transferred to a horizontal shot sleeve of the machine, which is preferably located in a vacuum environment and the molten material is injected under pressure into a reusable mold. We have found that the process of pouring and injecting the molten material in one or two seconds works well in a die casting machine having an unheated shot sleeve.

[0035] In order to transfer molten material from the crucible to a shot sleeve 30 of the apparatus (step 48 - FIG. 4), the crucible is mounted for translation (arrow 31 in FIG. 3), and also for pivotal movement (arrow 33 of FIG. 2) about a pouring axis, and in turn is mounted to a motor (not shown) for rotating the crucible to pour molten material from the crucible through a pour hole 32 of the shot sleeve 30. Translation of the crucible occurs between the melt chamber 20 in which material is melted and a position in a separate vacuum chamber 34 in which the shot sleeve is located. The pour chamber 34 is also maintained as a non-reactive environment, preferably a vacuum environment with a pressure level less than 100 µm and more preferably less than 50 µm. The melt chamber 20 and pour chamber 34 are separated by a gate valve or other suitable means (not shown) to minimize the loss of vacuum in the event that one chamber is exposed to atmosphere, e.g.. to gain access to a component in the particular chamber. While the illustrated embodiment includes separate melting and pouring chambers, it is also possible to perform melting and pouring in a single chamber. We prefer to use separate chambers in order to minimize the loss of vacuum environment in the event that a given component must be exposed to atmosphere, e.g.. to service the melting unit or the shot sleeve or to remove a casting.

[0036] As noted above, the molten material is transferred from the crucible 24 into the shot sleeve 30 through a pour hole 34. The shot sleeve 30 is coupled to a multipart, reusable die 36, which defines a die cavity 38 A sufficient amount of molten material is poured into the shot sleeve to fill the die cavity, which may include one part or more than one part. We have successfully cast as many as 12 parts in a single shot, e.g., using a 12 cavity die.

[0037] The illustrated die 36 includes two sections. 36a. 36b (but may include more sections), which cooperate to define the die cavity 38, for example in the form of a compressor blade or vane for a gas turbine engine. The die 36 is also preferably coupled directly to the vacuum source and also through the shot sleeve to enable evacuation of the die prior to injection of the molten metal. The die may be located in a vacuum chamber, instead of or in addition to being coupled directly to a vacuum source. One section of the two sections 36a, 36b of the die is typically fixed, while the other part is movable relative to the one section, for example by a hydraulic assembly (not shown). The die preferably includes ejector pins (not shown) to facilitate ejecting solidified material from the die. The die may also include a stripper mechanism (not shown) for removing casting material from the die while the material is still hot, to further reduce thermal loads on the die.

[0038] The die may be composed of various materials, and should have good thermal conductivity, and be relatively resistant to erosion and chemical attack from injection of the molten material. A comprehensive list of possible materials would be quite large, and includes materials such as metals, ceramics, graphite, ceramic matrix composites and metal matrix composites. Each of various die material has attributes. e.g.. case of machining, strength at elevated temperatures and compromises of the two, that makes it desirable for different applications. For titanium, we currently prefer to use dies composed of mild carbon steel, e.g.. 1018, due to its low cost and ease of machining. Coatings and surface treatments may be employed to enhance apparatus performance and the quality of resulting parts. The die may also be attached to a source of coolant such as water or a source of heat such as oil (not shown) to thermally manage the die temperature during operation. In addition, a die lubricant may be applied to one or more selected parts of the die and the die casting apparatus. Any lubricant should generally improve the quality of resultant cast articles, and more specifically should be resistant to thermal breakdown, so as not to contaminate the material being injected.

[0039] Molten metal is then transferred from the crucible to the shot sleeve. A sufficient amount of molten metal is poured into the shot sleeve to partially fill the sleeve, and subsequently to fill the die. Preferably, the sleeve is less than 50% filled, more preferably less than about 40% filled, and most preferably less than 30% filled.

[0040] An injection device, such as a plunger 40 cooperates with the shot sleeve 30 and hydraulics or other suitable assembly (not shown) drive the plunger in the direction of arrow 42, to move the plunger between the position illustrated by the solid lines and the position indicated by dashed lines, and thereby inject the molten material under pressure from the sleeve 30 into the die cavity 38 (step 50 - FIG. 4). In the position illustrated by solid lines, the plunger and sleeve cooperate to define a volume that is substantially greater than the amount of molten material that will be injected. Preferably, the sleeve volume is at least twice the volume of material to be injected, more preferably at least three times. Accordingly, the volume of molten material transferred from the crucible to the sleeve fills less than one half and most preferably less than about one third of the sleeve volume. Since the sleeve is only partially filled, any material or skin that solidifies on the sleeve forms only a partial cylinder, e.g., an open arcuate surface, and is easily scraped or crushed during metal injection, and reincorporated into the molten material. For injection, we have used plunger speeds of between about 30 inches per second (ips) and 300 ips/ 0.77 - 7.7 m/s (with a shot sleeve having an inner diameter of about 3 inches/7.6 cm), and currently prefer to use a plunger speed of between about 50 - 175 inches per second (ips)/1.28 - 4.5 m/s. The plunger is typically moved at a pressure of at least 1200 psi/ 8.4 MPa, and more preferably at least 1500 psi/ 10.5 MPa. As the plunger approaches the ends of its stroke when the die cavity is filled, it begins to transfer pressure to the metal. It may then be desirable to intensify the pressure to ensure complete filling of the mold cavity, the particular intensification parameters will depend upon the desired result. Intensification is performed to minimize porosity, and to reduce or eliminate any material shrinkage during cooling. We have used intensification above 1500 psi with satisfactory results. After a sufficient period of time has elapsed to ensure solidification of the material in the die, the ejector pins (not shown) are actuated to eject parts from the die (step 52 - FIG. 4).

[0041] As is known in the art, cast articles typically include some porosity, generally up to a few percent. Accordingly, and particularly where such articles are used in more demanding applications, such as compressor airfoils for gas turbine engines, there is a need to reduce and preferably eliminate porosity and otherwise treated as needed (step 54 - FIG. 4). The parts are therefore preferably hot isostatically pressed (HIP'd) as described above to reduce and substantially eliminate porosity in the as cast parts. For titanium alloy articles, we generally prefer to HIP at a temperature of above about 1500 - 1600 F/ 815 - 871 °C (and below the beta transus temperature of about 1850 F/ 1010 °C where it is desired to maintain existing beta phase), at a pressure of at least 14 ksi/ 98 MPA, more preferably above 14.5 ksi/ 101.5 MPa, and for at least 2 hours.

[0042] If desired, the articles may then be heat treated. Actual heat treatment and HIP parameters may be varied depending upon the desired application for the article and target cycle time for the process, however the temperature, pressure and time used during HIP must be sufficient to eliminate substantially all porosity in the cast articles, but not to allow significant grain growth.

[0043] As noted above, for airfoils composed of die cast Ti 6-4, the articles may be heated to a temperature of between about 1500-1600 F/ 815 - 871 °C in an inert environment, e.g., argon or vacuum, for at least 2 hours. For airfoils composed of die cast Ti 6-2-4-2, the articles are preferably heated to a temperature of between about 1000-1200 F/ 538 - 650 °C, more preferably about 1100 F in an inert environment, e.g., argon or vacuum, for at least 8 hours.

[0044] The parts are inspected (step 56 - FIG. 4) using conventional inspection techniques, e.g., by fluorescent penetrant inspection (FPI), radiographic, visual, and after passing inspection may be used or further treated/re-treated if necessary (step 58 - FIG. 4).

[0045] In accordance with the present invention, articles prepared in accordance with the present invention are characterized by a stable, fine grain microstructure. The particular, preferred average grain size and maximum allowable grain size will depend upon the application and cross sectional thickness of the part, e.g., whether the article is intended for use in a gas turbine engine versus other application, rotating vs. non-rotating parts, operating in lower temperature versus higher temperature environments. For gas turbine engine components, such as compressor blades and vanes, the average grain size is typically ASTM 0 or smaller, more preferably ASTM 3 or smaller, although the specific size will depend upon the particular part.

[0046] The articles, such as blades and vanes, in accordance with the present invention are characterized by an absence of flow lines. It should be noted that the articles may be thermomechanically processed after casting, if desired. In other words, the die cast articles may subsequently serve as pre-forms for use in a forging operation. In order to maximize cost savings associated with the present invention, we prefer that the die cast articles be cast to near net shape, so as to minimize post-casting work and associated expense performed on the articles.

[0047] In addition, the die cast articles may be processed to heat any residual casting porosity that may be present, such as by isostatic pressing operations such as hot isostatic pressing (HIP). Careful selection of HIP parameters, such as temperature, pressure and time is required to heal any porosity without altering the fine grain, (predominately) transformed beta microstructure. The temperature must be sufficiently high to enable closing of the porosity under pressure, e.g.. to enable creep, but not so high as to enable recrystallization of the material, e.g., below the beta transus temperature of the titanium alloy.

[0048] In the case of Ti 6-4, the HIP temperature preferably should not exceed 1750° F/ 950 °C, and is more preferably between about 1550 - 1650 ° F/ 843 - 900 °C. Ti 6-4 may also be annealed at about 1550 F/ 843 °C in a non-reactive environment, preferably argon or vacuum, for at least two hours after HIP'ing. In the case of Ti 6-2-4-2, the HIP temperature should not exceed 1850° F/1010 °C, and is more preferably between 1650 - 1750 ° F/ 900 - 950 °C. Ti 6-2-4-2 may be heat treated at about 1100 F/ 595 °C in a non-reactive environment, preferably argon or vacuum, for at least 8 hours

[0049] Additional post cast processing may also be performed, such as chemical milling of the surface to remove surface contaminants, media processing to improve surface finish, and additional thermal cycles to achieve a particular balance of mechanical properties. Such additional processing will vary on factors such as alloy composition and desired properties.

[0050] Die cast articles composed of Ti 6-4 were prepared in accordance with the present invention, as discussed in more detail below. The articles included compressor airfoils and test bars, and also included the above-post cast processing. Exemplary microstructures of a test bar and of an airfoil are illustrated in FIGS. 5 and 6. The microstructure of a corresponding airfoil composed of forged Ti 6-4 is illustrated in FIG. 7. Testing of the articles has confirmed that properties were comparable to those of corresponding forged articles. While the particular properties required will depend upon the use to which any particular die cast article is to be put, die cast articles to be used in place of forged articles have properties comparable to those of corresponding forged articles.

[0051] Results of test from the die cast articles were compared to results from specimens machined from corresponding forged articles, and the results are shown in FIGS. 8, 9. 10 and 11.

[0052] One titanium alloy used for aerospace applications is Ti-6A1-4V ("Ti 6-4"), which broadly includes about 4 - 8 w/o (weight percent) Al, 3 - 5 w/o V, balance generally titanium and traces of other elements.

[0053] For higher temperature applications, where improved creep properties are needed, Ti 6AI-2Sn-4Zr-2Mo ("Ti 6-2-4-2") may be used and broadly includes about 5 - 7 w/o Al, about 1.5 - 2.5 w/o Sn (tin), about 3.0 - 5.0 w/o Zr, about 1.5 - 2.5 w/o Mo. balance generally titanium and traces of other elements.

[0054] Other Ti alloys include Ti 8-1-1 and titanium aluminides. Ti 8-1-1 broadly includes about 7.35-8.35 w/o Al, 0.75-1.25 w/o Mo and 0.75-1.25 w/o V. balance generally titanium and traces of other elements.

[0055] Broadly, titanium aluminides are composed primarily of titanium and aluminum in stoichiometric amounts, having compositions such as TiAl and TiAl3. In general, die cast titanium aluminides may find use in a variety of applications were low density and moderate strength are required and the application temperature is moderate, in the range of about 500 - 1700° F/ 260 - 925 °C, and currently-envisioned applications include coverplates and heat shields.

[0056] In the case of compressor airfoils, die cast airfoils have comparable strength and impact properties compared to those exhibited by corresponding forged articles. In addition, such components have comparable durability properties, such as fatigue strength, and particularly high cycle fatigue capability. Fatigue tests also compared die cast Ti 6-4 and corresponding forged parts, and as indicated in FIGS. 10 and I 1 the die cast articles exhibit smooth and notched fatigue lives comparable to forged articles. Again, the above values will differ depending upon the particular use to which the articles are being put.

[0057] Die cast articles composed of Ti 6-2-4-2 were also prepared in accordance with the present invention, as discussed in more detail below. The articles included compressor blades and vanes and test bars, and also included the above-post cast processing. Exemplary microstructures of a test bar and of an airfoil are illustrated in FIGS. 12 and 13. The microstructure of a corresponding airfoil composed of forged Ti 6-2-4-2 is illustrated in FIG. 14.

[0058] Turning generally to FIG. 15. die cast articles composed of Ti 6-2-4-2 to be used as compressor blades and vanes have strength and impact properties comparable to those exhibited by corresponding forged articles produced for this application. In addition, such components have comparable durability properties, such as fatigue strength, and particularly high cycle fatigue capability. Fatigue tests also compared die cast Ti 6-2-4-2 and corresponding forged parts, and indicated that die cast articles exhibit similar properties relative to corresponding forged articles.

[0059] The above examples support and illustrate that die casting may be used to produce articles from a broad range of titanium alloy compositions. The above examples support and illustrate that die casting may be used to produce articles composed of a broad range of titanium alloy compositions. In further support, articles have also been die cast from Ti 8-1-I. Exemplary microstructure of die cast Ti 8-1-1 is illustrated in FIG. 13. Fatigue tests comparing die cast Ti 8- 1 -1 and corresponding forged parts are expected to indicate that the die cast articles exhibit comparable properties to forged articles.

[0060] Articles composed of various nickel base and cobalt base superalloys have also been prepared in accordance with the method of the present invention.

[0061] One nickel base superalloys is Inconel 718 (IN 718), which in broad terms is composed in weight percent of about 0.01 - 0.05 Carbon (C), up to about 0.4 Manganese (Mn), up to about 0.2 Silicon (Si), 13 - 25 Chromium (Cr), up to about 1.5 Cobalt (Co), 2.5 - 3.5 Molybdenum (Mo), 5.0 - 5.75 (Columbium (Cb) + Tantalum (Ta), 0.7 - 1.2 Titanium (Ti), 0.3 - 0.9 Aluminum (Al), up to about 21 Iron (Fe), balance essentially Ni. Other alloys may also be employed, such as IN 713 having a nominal composition in weight percent, of up to about 0.025 Carbon (C), up to about 0.4 Manganese (Mn), up to about 0.4 Silicon (Si), 12 - 16 Chromium (Cr), 3 - 6 Molybdenum (Mo), 0.8 - 3.5 (Columbium (Cb) + Tantalum (Ta)), 0.7 - 1.3 Titanium (Ti), 5.25 - 6.75 Aluminum (Al), up to about 1 Iron (Fe), balance essentially Ni and Cobalt (Co).

[0062] Waspaloy is another material useful for such applications, and is disclosed for example in commonly-owned U.S. Pat. Nos. 4,574,015 and 5,120,373, which are expressly incorporated by reference herein. Generally, Waspaloy has a composition in weight percent, of about 0.02 - 0.15 Carbon (C), 12 - 20 Chromium (Cr), 10 - 20 Cobalt (Co), 2-5.5 Molybdenum (Mo), 3 - 7 Titanium (Ti), 1.2 - 3.5 Aluminum (Al), 0.01 0.15 Zirconium (Zr), 0.002 - 0.05 Boron (B), balance essentially Ni.

[0063] Another alloy is B-1900, which has a nominal composition in weight percent of about 8 Cr, 10 Co, 6 Mo, 4 Ta, 6 Al, 1 Ti, 0.1 C, 0.015 B, and 0.1 Zr. See, e.g., Sims and Hagel, The Superalloys, (Wiley & Sons 1972), pp. 596-7. Cobalt base alloys, such as MAR-M-509 are also used in higher temperature applications. MAR-M-509 has a nominal composition, in weight percent, of about 23.5 Chromium (Cr), 10 Nickel (Ni), 7 Tungsten (W), 3.5 Tantalum (Ta), 0.2 Titanium (Ti), 0.5 Zirconium, balance essentially Cobalt. See, e.g., Sims and Hagel.

[0064] IN 939 is another nickel base alloy, useful up to about 1500 F, and has a nominal composition of about 22.5 Cr, 19 Co, 6 Mo. 2 Al, 3.7 Ti, 2 W, 3.3 (Cb + Ta), 0.15 C, 0.005 B. balance generally nickel. IN 939 is difficult if not impossible to forge. Gatorized Waspaloy is an advanced Waspaloy composition developed to provide improved strength and temperature capability over conventional Waspaloy. See, U.S. Pat. Nos. 4,574.015 and 5,120,373. It has a general composition, in weight percent of Chromium 15 .00 - 17 .00, Cobalt 12 .00 - 15 .00. Molybdenum 3 .45 - 4 .85. Titanium 4 .45 - 4 .75, Aluminum 2.00 - 2.40. Gator Waspaloy may also small amounts of other elements.

[0065] As a result of our work with these alloys, we believe that several conditions are important to produce good quality castings. The melting, pouring and injection of material, particularly for reactive materials such as titanium alloys, must be performed in a non-reactive environment, and we prefer to perform these operations in a vacuum environment maintained at a pressure preferably less than 100 µm and more preferably less than 50 µm. The amount of superheat should be sufficient to ensure that the material remains substantially and completely molten from the time it is poured until it is injected, but also to enable rapid cooling and formation of small grains once injected. Due to the relatively low superheat, molten metal transfer and injection must be rapid enough to occur prior to metal solidification. The resulting microstructure such as grain size appears to correspond to the sectional thickness of the part being cast as well as the die materials utilized and the superheat used, i.e., thinner sections tend to include smaller grains and thicker sections (particularly internal portions of thicker sections) tend to include larger grains. Higher thermal conductivity die materials result in articles having smaller grains, as does use of lower superheats. We believe that this results from relative cooling rates. The rate at which the plunger is moved, and correspondingly the rate at which material is injected into the mold appears to affect the surface finish of the articles as cast, although the design of the gating as well as the die material may also play a role in combination with the injection rate.

[0066] Die casting high melting temperature materials provides other significant advantages over forging. From the standpoint of required equipment, forging requires the production of multiple dies to make a new part, at significant cost. In contrast, only a single die set is required per part, at significantly reduced expense relative to forging. The time required to produce a part, from ingot to finished part, is reduced significantly, since there is no need to prepare specially tailored billets of material, and casting broadly is performed in a single step, as opposed to multiple forging operations In die casting, multiple parts can be produced in a single casting. Die casting enables production of parts having more complex three dimensional shapes, thereby enabling new software design technology to be applied to and exploited in areas such as gas turbine engines and enabling production of more efficient airfoils and other components. We believe that die casting will enable the production of articles having complex shapes utilizing materials that are difficult or impossible to forge into those shapes. Moreover, die cast parts can be produced nearer to their finished shape, and with a superior surface finish, which minimizes post forming finishing operations, all of which also reduces the cost of producing such parts.

[0067] While the present invention has been described above in some detail, numerous variations and substitutions may be made without departing from the scope of the invention as defined by the following claims. Accordingly, it is to be understood that the invention has been described by way of illustration and not by way of limitation.

Claims

1. A process of making a high melting temperature material or reactive material in a die casting machine (18) having a melting unit (20) for melting the material, a generally cylindrical, horizontal shot sleeve (30) in fluid communication with a multi part die (36), a transfer unit for transferring molten material from the melting unit to the sleeve, a die-cavity-defining die (36) for receiving molten material, and a plunger (40) in a sealing and moveable engagement with the sleeve (30) for forcing molten material from the shot sleeve (30) into the die cavity, the sleeve being moveable between a first position in which the plunger (40) and sleeve (30) define a sleeve fill volume and a material injected position in which material is injected into the die (36), the method comprising the steps of:

maintaining the melting unit (20), the shot sleeve (30) and the die cavity (36) in a non-reactive environment;

melting the material in the melting unit (20), the molten material being melted with a superheat less than about 200°F/95°C;

transferring material from the melting unit (20) to the shot sleeve (30) so as to fill less than the entire sleeve fill volume; and

injecting the molten material into the die cavity (36) by moving the plunger (40) between the first and second positions and solidifying the molten material in the die cavity (36), characterised in that the method further comprises the step of:

controlling the temperature of the die (36) so as to solidify the molten material injected into the die within less than about two seconds, whereby the article has a transformed beta microstructure and an absence of flow lines.

2. The method of claim 1, wherein the step of maintaining includes maintaining the melting unit (20), the shot sleeve (30) and the die cavity (36) in a vacuum environment at a pressure less than about 100µm.

3. The method of claim 2, wherein the step of maintaining includes maintaining the melting unit (20), the shot sleeve (30) and the die cavity (36) of a low pressure environment less than about 50µm.

4. The method of any preceding claim, wherein the step of maintaining includes separately maintaining the melting unit (20), the shot sleeve (30) and the die cavity (36) in a non-reactive environment.

5. The method of any preceding claim, wherein the step of melting includes the step of heating the material to at least 2000°F/1093°C.

6. The method of claim 5, wherein the step of melting includes heating the material to at least 2500°F/1370°C.

7. The method of claim 6, wherein the step of melting includes heating the material to at least 3000°F/1650°C.

8. The method of any of claims 1 to 4, wherein the step of melting includes melting a material having a composition of about 4-8 w/o Al and 3-5 w/o V, balance generally Ti.

9. The method of any of claims 1 to 4, wherein the step of melting includes melting a material having a composition of about 5 - 7 w/o Al, about 1.5 - 2.5 w/o Sn (tin), about 3.0 - 5.0 w/o Zr, about 1.5 - 2.5 w/o Mo, balance generally titanium.

10. The method of any of claims 1 to 4, wherein the step of melting includes melting a material having a composition of about 7 - 8.5 w/o A1, 0.5 - 1.5 w/o Mo and 0.5 - 1.5 w/o V, balance generally titanium.

11. The method of any of claims 1 to 4, wherein the material is selected from the group consisting essentially of titanium alloys, nickel base superalloys, cobalt base superalloys, iron base superalloys and combinations thereof.

12. The method of any of claims 1 to 4, wherein the material is composed of up to about 0.05 Carbon (C), up to about 0.4 Manganese (Mn), up to about 0.2 Silicon (Si), 13 - 25 Chromium (Cr), up to about 1.5 Cobalt (Co), 2.5 - 3.5 Molybdenum (Mo), 5.0- 5.75 (Columbium (Cb) + Tantalum (Ta)), 0.7 - 1.2 Titanium (Ti), 0.3 - 0.9 Aluminium (Al), up to about 21 Iron (Fe), balance essential Ni.

13. The method of any of claims 1 to 4, wherein the material is composed of up to about 0.025 Carbon (C), up to about 0.4 Manganese (Mn), up to about 0.4 Silicon (Si), 12 - 16 Chromium (Cr), 3 - 6 Molybdenum (Mo), 0.8 - 3.5 (Columbium (Cb) + Tantalum (Ta)), 0.7 - 1.3 Titanium (Ti), 5.25 - 6.75 Aluminium (Al), up to about 1 Iron (Fe), balance essentially Ni and Cobalt (Co).

14. The method of any of claims 1 to 4, wherein the material is composed of up to about 0.15 Carbon (C), 12 - 20 Chromium (Cr), 10 - 20 Cobalt (Co), 2 - 5.5 Molybdenum (Mo), 3 - 7 Titanium (Ti), 1.2 - 3.5 Aluminium (Al), 0.01 - 0.15 Zirconium (Zr), 0.002 - 0.05 Boron (B), balance essentially Ni.

15. The method of any of claims 1 to 4, wherein the material is composed of about 8 Cr, 10 Co, 6 Mo, 4 Ta, 6 Al, 1 Ti, 0.1 C, 0.015 B, and 0.1 Zr.

16. The method of any of claims 1 to 4, wherein the material is composed of about 23.5 Chromium (Cr), 10 Nickel (Ni), 7 Tungsten (W), 3.5 Tantalum (Ta), 0.2 Titanium (Ti), 0.5 Zirconium, balance essentially Cobalt.

17. The method of any preceding claim, wherein the resulting article comprises a gas turbine engine component.

18. The method of claim 17, wherein the resulting article comprises a compressor component.

19. The method of claim 18, wherein the resulting article is selected from the group consisting essentially of blades and vanes.

20. The method of any preceding claim, wherein the step of injecting includes moving the plunger through the sleeve at a rate of between about 30 and 250 inches per second (0.77 - 6.4 m/s).

21. The method of any preceding claim, wherein the step of injecting includes moving the plunger through the sleeve with a pressure of between about 500 - 1500 psi (3.5 - 10.5 MPa).

22. The method of any preceding claim, wherein the step of injecting includes increasing the pressure at the end of the plunger stroke.

23. The method of any preceding claim, further comprising the step of:

ejecting the solidified articles from the die; and

removing any porosity in the articles.

24. The method of claim 23, wherein the step of removing porosity comprises the steps of:

heating the articles to at least about 1400°F/760°C and exerting a pressure on articles of at least about 14 ksi/98 MPa; and

maintaining the heat and pressure for at least about 2 hours.

25. The method of claim 24, further comprising the step of subsequently heating the article to a temperature of at least about 1500°F/815°C in a non-reactive environment for at least about 2 hours.

26. The method of any preceding claim, wherein the step of melting includes melting the material with a superheat less than about 100°F/37°C.

27. The method of claim 26, wherein the step of melting includes melting the material with a superheat less than about 50°F/10°C.

Ansprüche

1. Verfahren zum Verarbeiten eines Materials mit hoher Schmelztemperatur oder eines reaktiven Materials in einer Druckgussmaschine (18) mit einer Schmelzeinheit (20) zum Schmelzen des Materials, einem im Wesentlichen zylindrischen horizontalen Schusskanal (30) in Fluidverbindung mit einer mehrteiligen Gießform (36), einer Überführungseinheit zum Überführen von geschmolzenem Material aus der Schmelzeinheit in den Kanal, einer den Gießform-Hohlraum definierenden Gießform (36) zum Aufnehmen von geschmolzenem Material, und einem Kolben (40) in abdichtendem und beweglichem Eingriff mit dem Kanal (30) zum Treiben von geschmolzenem Material aus dem Schusskanal (30) in den Gießform-Hohlraum, wobei der Kanal zwischen einer ersten Stellung in der der Kolben (40) und der Kanal (30) ein Kanal-Füllvolumen definieren, und einer Material-Einspritzstellung, in der Material in die Gießform (36) eingespritzt ist, bewegbar ist, wobei das Verfahren folgende Schritte aufweist:

Halten der Schmelzeinheit (20), des Schusskanals (30) und des Gießform-Hohlraums (36) in einer nicht-reaktiven Umgebung;

Schmelzen des Materials in der Schmelzeinheit (20), wobei das geschmolzene Material mit einer Überhitzung von weniger als etwa 200°F/95°C geschmolzen wird;

Überführen von Material aus der Schmelzeinheit (20) in den Schusskanal (30), um weniger als das gesamte Kanal-Füllvolumen zu füllen; und

Einspritzen des geschmolzenen Materials in den Gießform-Hohlraum (36) durch Bewegen des Kolbens (40) zwischen der ersten und der zweiten Stellung und Festwerden-Lassen des geschmolzenen Materials in dem Gießform-Hohlraum (36), dadurch gekennzeichnet, dass das Verfahren außerdem folgenden Schritt aufweist:

Kontrollieren der Temperatur der Gießform (36) so, dass das in die Gießform eingespritzte geschmolzene Material innerhalb von weniger als 2 s fest wird, wodurch der Gegenstand eine inverse beta-Mikrostruktur und ein Fehlen von Fließlinien aufweist.

2. Verfahren nach Anspruch 1, bei dem der Schritt des Haltens ein Halten der Schmelzeinheit (20), des Schusskanals (30) und des Gießform-Hohlraums (36) in einer Vakuumumgebung bei einem Druck von weniger als etwa 100 µm umfasst.

3. Verfahren nach Anspruch 2, bei dem der Schritt des Haltens ein Halten der Schmelzeinheit (20), des Schusskanals (30) und des Gießform-Hohlraums (36) in einer Niederdruck-Umgebung von weniger als etwa 50 µm umfasst.

4. Verfahren nach irgendeinem vorangehenden Anspruch, bei dem der Schritt des Haltens ein separates Halten der Schmelzeinheit (20), des Schusskanals (30) und des Gießform-Hohlraums (36) in einer nicht-reaktiven Umgebung umfasst.

5. Verfahren nach irgendeinem vorangehenden Anspruch, bei dem der Schritt des Schmelzens den Schritt des Erhitzens des Materials auf mindestens 2000°F/1093°C umfasst.

6. Verfahren nach Anspruch 5, bei dem der Schritt des Schmelzens ein Erhitzen des Materials auf mindestens 2500°F/1370°C umfasst.

7. Verfahren nach Anspruch 6, bei dem der Schritt des Schmelzens ein Erhitzen des Materials auf mindestens 3000°F/1650°C umfasst.

8. Verfahren nach einem der Ansprüche 1 bis 4, bei dem der Schritt des Schmelzens ein Schmelzen eines Materials mit einer Zusammensetzung von etwa 4 bis 8 Gew.-% Al und 3 bis 5 Gew.-% V, Rest im Wesentlichen Ti, umfasst.

9. Verfahren nach einem der Ansprüche 1 bis 4, bei dem der Schritt des Schmelzens ein Schmelzen eines Materials mit einer Zusammensetzung von etwa 5 bis 7 Gew.-% Al, etwa 1,5 bis 2,5 Gew.-% Sn (Zinn), etwa 3,0 bis 5,0 Gew.-% Zr, etwa 1,5 bis 2,5 Gew.-% Mo, Rest im Wesentlichen Titan, umfasst.

10. Verfahren nach einem der Ansprüche 1 bis 4, bei dem der Schritt des Schmelzens ein Schmelzen eines Materials mit einer Zusammensetzung von etwa 7 bis 8,5 Gew.-% Al, 0,5 bis 1,5 Gew.-% Mo und 0,5 bis 1,5 Gew.% V, Rest im Wesentlichen Titan, umfasst.

11. Verfahren nach einem der Ansprüche 1 bis 4, bei dem das Material ausgewählt wird aus der Gruppe, die im Wesentlichen aus Titanlegierungen, Superlegierungen auf Nickelbasis, Superlegierungen aus Cobaltbasis, Superlegierungen auf Eisenbasis und Kombinationen davon besteht.

12. Verfahren nach einem der Ansprüche 1 bis 4, bei dem das Material aus bis zu etwa 0,05 Kohlenstoff (C), bis zu etwa 0,4 Mangan (Mn), bis zu etwa 0,2 Silicium (Si), 13 bis 25 Chrom (Cr), bis zu etwa 1,5 Cobalt (Co), 2,5 bis 3,5 Molybdän (Mo), 5,0 bis 5,75 (Columbium (Cb) + Tantal (Ta)), 0,7 bis 1,2 Titan (Ti), 0,3 bis 0,9 Aluminium (Al), bis zu etwa 21 Eisen (Fe), Rest im Wesentlichen Ni, besteht.

13. Verfahren nach einem der Ansprüche 1 bis 4, bei dem das Material aus bis zu etwa 0,025 Kohlenstoff (C), bis zu etwa 0,4 Mangan (Mn), bis zu etwa 0,4 Silicium (Si), 12 bis 16 Chrom (Cr), 3 bis 6 Molybdän (Mo), 0,8 bis 3,5 (Columbium (Cb) + Tantal (Ta)), 0,7 bis 1,3 Titan (Ti), 5,25 bis 6,75 Aluminium (Al), bis zu etwa 1 Eisen (Fe), Rest im Wesentlichen Ni und Cobalt (Co), besteht.

14. Verfahren nach einem der Ansprüche 1 bis 4, bei dem das Material aus bis zu etwa 0,15 Kohlenstoff (C), 12 bis 20 Chrom (Cr), 10 bis 20 Cobalt (Co), 2 bis 5,5 Molybdän (Mo), 3 bis 7 Titan (Ti), 1,2 bis 3,5 Aluminium (Al), 0,01 bis 0,15 Zirconium (Zr), 0,002 bis 0,05 Bor (B), Rest im Wesentlichen Ni, besteht.

15. Verfahren nach einem der Ansprüche 1 bis 4, bei dem das Material aus etwa 8 Cr, 10 Co, 6 Mo, 4 Ta, 6 Al, 1 Ti, 0,1 C, 0,015 B und 0,1 Cr besteht.

16. Verfahren nach einem der Ansprüche 1 bis 4, bei dem das Material aus etwa 23,5 Chrom (Cr), 10 Nickel (Ni), 7 Wolfram (W), 3,5 Tantal (Ta), 0,2 Titan (Ti), 0,5 Zirconium, Rest im Wesentlichen Cobalt, besteht.

17. Verfahren nach irgendeinem vorangehenden Anspruch, bei dem der sich ergebende Gegenstand ein Gasturbinenmaschinen-Bauteil aufweist.

18. Verfahren nach Anspruch 17, bei dem der sich ergebende Gegenstand ein Kompressor-Bauteil aufweist.

19. Verfahren nach Anspruch 18, bei dem der sich ergebende Gegenstand ausgewählt wird aus der Gruppe, die im Wesentlichen aus Laufschaufeln und Leitschaufeln besteht.

20. Verfahren nach irgendeinem vorangehenden Anspruch, bei dem der Schritt des Einspritzens ein Bewegen des Kolbens durch den Kanal mit einer Geschwindigkeit von zwischen etwa 30 und 250 Inch/s (0,77 bis 6,4 m/s) umfasst.

21. Verfahren nach irgendeinem vorangehenden Anspruch, bei dem der Schritt des Einspritzens ein Bewegen des Kolbens durch den Kanal mit einem Druck von zwischen etwa 500 bis 1500 psi (3,5 bis 10,5 MPa) umfasst.

22. Verfahren nach irgendeinem vorangehenden Anspruch, bei dem der Schritt des Einspritzens ein Erhöhen des Drucks am Ende des Kolbenhubs umfasst.

23. Verfahren nach irgendeinem vorangehenden Anspruch, außerdem aufweisend den Schritt des:

Ausstoßens der fest gewordenen Gegenstände aus der Gießform; und

des Entfernens irgendwelcher Porosität in den Gegenständen.

24. Verfahren nach Anspruch 23, bei dem der Schritt des Entfernens von Porosität folgende Schritte aufweist:

Erhitzen der Gegenstände auf mindestens etwa 1400°F/760°C und Ausüben eines Drucks von mindestens etwa 14 ksi/98 MPa auf die Gegenstände; und

Aufrechterhalten der Hitze und des Drucks für mindestens etwa 2 h.

25. Verfahren nach Anspruch 24, außerdem aufweisend den Schritt des nachfolgend Erhitzens des Gegenstands auf eine Temperatur von mindestens etwa 1500°F/815°C in einer nicht-reaktiven Umgebung für mindestens etwa 2 h.

26. Verfahren nach irgendeinem vorangehenden Anspruch, bei dem der Schritt des Schmelzens ein Schmelzen des Materials mit einer Überhitzung von weniger als etwa 100°F/37°C umfasst.

27. Verfahren nach Anspruch 26, bei dem der Schritt des Schmelzens ein Schmelzen des Materials mit einer Überhitzung von weniger als etwa 50°F/10°C umfasst.

Revendications

1. Procédé de fabrication d'un matériau à température de fusion élevée ou d'un matériau réactif dans une machine de moulage par pression (18), ayant une unité de fusion (20) en vue de la fusion du matériau, un manchon d'injection horizontale, en général cylindrique (30) en communication fluide avec une matrice à plusieurs parties (36), une unité de transfert en vue du transfert du matériau fondu de l'unité de fusion au manchon, une matrice définissant la cavité de la matrice (36) pour la réception du matériau fondu, et un plongeur (40) dans un engagement étanche et mobile avec le manchon (30) pour forcer le matériau fondu hors du manchon d'injection (30) dans la cavité de la matrice, le manchon étant mobile entre une première position dans laquelle le plongeur (40) et le manchon (30) définissent un volume de remplissage du manchon et une position d'injection de matériau dans laquelle le matériau est injecté dans la matrice (36), le procédé comprenant les étapes:

de maintien de l'unité de fusion (20), du manchon d'injection (30) et de la cavité de la matrice (36) dans un environnement non réactif;

de fusion du matériau dans l'unité de fusion (20), le matériau fondu étant fondu avec une super-chaleur inférieure à environ 200°F/95°C;

de transfert du matériau de l'unité de fusion (20) au manchon d'injection (30) de manière à remplir moins que le volume entier de remplissage du manchon; et

d'injection du matériau fondu dans la cavité de la matrice (36) en déplaçant le plongeur (40) entre la première et le deuxième positions et de solidification du matériau fondu dans la cavité de la matrice (36), caractérisé en ce que le procédé contient en sus l'étape :

de contrôle de la température de la matrice (36) de manière à solidifier le matériau fondu injecté dans la matrice en moins de deux secondes environ, l'article présentant une microstructure bêta transformée et une absence de lignes de flux.

2. Procédé selon la revendication 1, dans lequel l'étape de maintien comprend le maintien de l'unité de fusion (20), du manchon d'injection (30) et de la cavité de la matrice (36) dans un environnement sous vide à une pression inférieure à environ 100µm.

3. Procédé selon la revendication 2, dans lequel l'étape de maintien inclut le maintien de l'unité de fusion (20), du manchon d'injection (30) et de la cavité de la matrice (36) dans un environnement à basse pression de moins de 50 µm environ.

4. Procédé selon l'une quelconque des revendications précédentes, dans lequel l'étape de maintien inclut le maintien séparé de l'unité de fusion (20), du manchon d'injection (30) et de la cavité de la matrice (36) dans un environnement non réactif.

5. Procédé selon l'une quelconque des revendications précédentes, dans lequel l'étape de fusion comprend l'étape de chauffage du matériau à au moins 2000°F/1093°C.

6. Procédé selon la revendication 5, dans lequel l'étape de fusion comprend le chauffage du matériau à au moins 2500°F/1370°C.

7. Procédé selon la revendication 6, dans lequel l'étape de fusion comprend le chauffage du matériau à au moins 3000°F/1650°C.

8. Procédé selon l'une quelconque des revendications 1 à 4, dans lequel l'étape de fusion comprend la fusion d'un matériau ayant une composition d'environ 4 - 8 pourcentage massique d'Al et 3 - 5 pourcentage massique de V, le reste étant en général du Ti.

9. Procédé selon l'une quelconque des revendications 1 à 4, dans lequel l'étape de fusion comprend la fusion d'un matériau ayant une composition d'environ 5 - 7 pourcentage massique d'Al, d'environ 1,5 - 2,5 pourcentage massique de Sn (étain), d'environ 3,0 - 5,0 pourcentage massique de Zr, d'environ 1,5 - 2,5 pourcentage massique de Mo, le reste étant du titane.

10. Procédé selon l'une quelconque des revendications 1 à 4, dans lequel l'étape de fusion comprend la fusion d'un matériau ayant une composition d'environ 7 - 8,5 pourcentage massique d'Al, de 0,5 - 1,5 pourcentage massique de Mo et de 0,5 - 1,5 pourcentage massique de V, le reste étant en général du titane.

11. Procédé selon l'une quelconque des revendications 1 à 4, dans lequel le matériau est sélectionné parmi le groupe constitué essentiellement d'alliages de titane, de superalliages à base de nickel, de superalliages à base de cobalt, de superalliages à base de fer et de combinaisons de ces derniers.

12. Procédé selon l'une quelconque des revendications 1 à 4, dans lequel le matériau est composé de jusqu'à environ 0,05 de carbone (C), jusqu'à environ 0,4 de manganèse (Mn), jusqu'à environ 0,2 de silicium (Si), de 13 - 25 de chrome (Cr), jusqu'à environ 1,5 de cobalt (Co), de 2,5 - 3,5 de molybdène (Mo), de 5,0-5,75 de (columbium (Cb) + tantale (Ta)), de 0,7 - 1,2 de titane (Ti), de 0,3 - 0,9 d'aluminium (Al), jusqu'à environ 21 de fer (Fe), le reste étant essentiellement du Ni.

13. Procédé selon l'une quelconque des revendications 1 à 4, dans lequel le matériau est composé de jusqu'à environ 0,025 de carbone (C), jusqu'à environ 0,4 de manganèse (Mn), jusqu'à environ 0,4 de silicium (Si), de 12 - 16 de chrome (Cr), de 3 - 6 de molybdène (Mo), de 0, 8 - 3,5 de (columbium (Cb) + tantale (Ta)), de 0,7 - 1,3 de titane (Ti), de 5,25 - 6,75 d'aluminium (Al), jusqu'à environ 1 de fer (Fe), le reste étant essentiellement du Ni et du cobalt (Co).

14. Procédé selon l'une quelconque des revendications 1 à 4, dans lequel le matériau est composé de jusqu'à environ 0,15 de carbone (C), de 12 - 20 de chrome (Cr), de 10 - 20 de cobalt (Co), de 2 - 5,5 de molybdène (Mo), de 3 - 7 de titane (Ti), de 1,2 - 3,5 d'aluminium (Al), de 0,01 - 0,15 de zirconium (Zr), de 0,002 - 0,05 de bore (B), le reste étant essentiellement du Ni.

15. Procédé selon l'une quelconque des revendications 1 à 4, dans lequel le matériau est composé d'environ 8 de Cr, 10 de Co, 6 de Mo, 4 de Ta, 6 d'Al, 1 de Ti, 0,1 de C, 0,015 de B, et 0,1 de Zr.

16. Procédé selon l'une quelconque des revendications 1 à 4, dans lequel le matériau est composé d'environ 23,5 de chrome (Cr), de 10 de nickel (Ni), de 7 de tungstène (W), de 3,5 de tantale (Ta), de 0,2 de titane (Ti), de 0,5 de zirconium, le reste étant essentiellement du cobalt.

17. Procédé selon l'une quelconque des revendications précédentes, dans lequel l'article résultant comprend un composant de moteur de turbine à gaz.

18. Procédé selon la revendication 17, dans lequel l'article résultant comprend un composant de compresseur.

19. Procédé selon la revendication 18, dans lequel l'article résultant est sélectionné parmi le groupe constitué essentiellement de pales et d'aubes.

20. Procédé selon l'une quelconque des revendications précédentes, dans lequel l'étape d'injection comprend le déplacement du plongeur à travers le manchon à une vitesse comprise entre environ 30 et 250 pouces par seconde (0,77 - 6,4 m/s).

21. Procédé selon l'une quelconque des revendications précédentes, dans lequel l'étape d'injection comprend le déplacement du plongeur à travers le manchon avec une pression comprise entre environ 500 - 1500 livres par pouce au carré (3,5 - 10,5 MPa).

22. Procédé selon l'une quelconque des revendications précédentes, dans lequel l'étape d'injection comprend l'augmentation de la pression à la fin de la course du plongeur.

23. Procédé selon l'une quelconque des revendications précédentes, comprenant en outre l'étape d'éjection des articles solidifiés à partir de la matrice et d'élimination d'une porosité quelconque dans les articles.

24. Procédé selon la revendication 23, dans lequel l'étape d'élimination de la porosité comprend les étapes:

de chauffage des articles à au moins environ 1400°F/760°C et d'application d'une pression sur les articles d'au moins environ 14 livres par pouce au carré/98 MPa; et

de maintien de la chaleur et de la pression pendant au moins environ 2 heures.

25. Procédé selon la revendication 24, comprenant en outre l'étape de chauffage subséquent de l'article à une température d'au moins environ 1500°F/815°C dans un environnement non réactif pendant au moins environ 2 heures.

26. Procédé selon l'une quelconque des revendications précédentes, dans lequel l'étape de fusion comprend la fusion du matériau à l'aide d'une super-chaleur inférieure à environ 100°F/37°C.

27. Procédé selon la revendication 26, dans lequel l'étape de fusion comprend la fusion du matériau à l'aide d'une super-chaleur environ inférieure à 50°F/10°C.

Drawing