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EP 2 938 448 B1 |
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EUROPEAN PATENT SPECIFICATION |
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Mention of the grant of the patent: |
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04.07.2018 Bulletin 2018/27 |
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Date of filing: 12.12.2013 |
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International Patent Classification (IPC):
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International application number: |
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PCT/US2013/074555 |
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International publication number: |
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WO 2014/105436 (03.07.2014 Gazette 2014/27) |
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MULLITE-CONTAINING INVESTMENT CASTING CORE
MULLITHALTIGER FEINGUSSKERN
NOYAU DE MOULAGE DE PRÉCISION À MODÈLE PERDU CONTENANT DE LA MULLITE
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Designated Contracting States: |
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AL AT BE BG CH CY CZ DE DK EE ES FI FR GB GR HR HU IE IS IT LI LT LU LV MC MK MT NL
NO PL PT RO RS SE SI SK SM TR |
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Priority: |
28.12.2012 US 201213729077
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Date of publication of application: |
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04.11.2015 Bulletin 2015/45 |
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Proprietor: United Technologies Corporation |
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Farmington, CT 06032 (US) |
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Inventor: |
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- BOCHIECHIO, Mario P.
Vernon, Connecticut 06066 (US)
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Representative: Dehns |
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St. Brides House
10 Salisbury Square London EC4Y 8JD London EC4Y 8JD (GB) |
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References cited: :
US-A- 3 833 385 US-A- 5 394 933 US-A1- 2003 075 300 US-A1- 2006 086 478 US-A1- 2010 122 789 US-B1- 8 286 689
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US-A- 4 767 479 US-A- 5 612 393 US-A1- 2005 070 651 US-A1- 2008 027 163 US-A1- 2010 276 103
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- DALLAVALLE J M ET AL: "Fitting Bimodal Particle Size Distribution Curves, Comparison
of methods", INDUSTRIAL AND ENGINEERING CHEMISTRY,, vol. 43, no. 6, 1 June 1951 (1951-06-01),
pages 1377-1380, XP002637120, DOI: 10.1021/IE50498A032
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| Note: Within nine months from the publication of the mention of the grant of the European
patent, any person may give notice to the European Patent Office of opposition to
the European patent
granted. Notice of opposition shall be filed in a written reasoned statement. It shall
not be deemed to
have been filed until the opposition fee has been paid. (Art. 99(1) European Patent
Convention).
|
BACKGROUND
[0001] This disclosure relates to investment casting and, more particularly, to investment
casting cores.
[0002] Investment casting is known and used to cast metallic components with relatively
complex geometries. For example, gas turbine engine components, such as airfoils that
have internal passages, are made by investment casting. To form the internal passages
or other relatively complex geometrical features, a core is provided which represents
a positive projection of negative features that are to be formed in the casting process.
A wax material is then provided around the core in the shape of the component to be
cast. A shell is then formed around the wax and the wax is removed to form a cavity
between the core and the surrounding shell into which molten metal is poured to form
the shape of the component. After solidification of the metal, the core is removed
using known techniques to provide the cast component.
[0003] US 2005/070651 discloses an investment casting core comprising a mullite-containing core body.
SUMMARY
[0004] An investment casting core according to an exemplary aspect of the present disclosure
includes a mullite-containing core body and characterised by the investment casting
core comprising a metallic core body joined to the mullite-containing core body, wherein
the coefficient of thermal expansion of the mullite-containing core body is within
2% of the coefficient of thermal expansion of the metallic core body.
[0005] In a further non-limiting embodiment of any of the foregoing examples, the mullite-containing
core body has, by weight, 40% or greater of mullite.
[0006] In a further non-limiting embodiment of any of the foregoing examples, the mullite-containing
core body has, by weight, 40-90% of mullite.
[0007] In a further non-limiting embodiment of any of the foregoing examples, the mullite-containing
core body has a material selected from the group consisting of alumina, silica, magnesia,
yttria, calcia, zirconium silicate and combinations thereof.
[0008] In a further non-limiting embodiment of any of the foregoing examples, the mullite-containing
core body has, by weight, 40-90% of mullite and 60-5% of silica.
[0009] In a further non-limiting embodiment of any of the foregoing examples, the mullite-containing
core body has a material selected from the group consisting of magnesia, yttria, calcia
and combinations thereof.
[0010] In a further non-limiting embodiment of any of the foregoing examples, the mullite-containing
core body has zirconium silicate.
[0011] In a further non-limiting embodiment of any of the foregoing examples, the metallic
core body is selected from the group consisting of molybdenum, tungsten, tantalum,
rhenium, niobium and combinations thereof.
[0012] In a further non-limiting embodiment of any of the foregoing examples, the mullite-containing
core body has, by weight, 80-90% mullite, 15-5% silica, 2.5- 10% alumina, 0-2.5% zircon,
0-5% of one or more of: calcia, magnesia and yttria.
[0013] In a further non-limiting embodiment of any of the foregoing examples, the mullite-containing
core body has a multi-modal or bi-modal grain size distribution.
[0014] A method of making an investment casting core according to an exemplary aspect of
the present disclosure includes: providing a mullite-containing powder; forming the
mullite-containing powder into a green body; and sintering the green body to form
a mullite-containing core body; and characterised by joining the mullite-containing
core body to a metallic core body, wherein the coefficient of thermal expansion of
the mullite-containing core body has a coefficient of thermal expansion within 2%
of the coefficient of thermal expansion of the metallic core body.
[0015] A further non-limiting embodiment of any of the foregoing examples includes providing
the mullite-containing powder in a blend with a binder, and the forming includes molding
the blend into the green body.
[0016] In a further non-limiting embodiment of any of the foregoing examples, the mullite-containing
powder has at least a bi-modal particle size distribution of mullite particles.
[0017] In a further non-limiting embodiment of any of the foregoing examples, the mullite-containing
powder has a material selected from alumina, silica, magnesia, yttria, calcia, zirconium
silicate and combinations thereof in a powder with at least a bi-modal particle size
distribution.
[0018] A further non-limiting embodiment of any of the foregoing examples includes selecting
a composition of the mullite-containing powder to obtain a coefficient of thermal
expansion in the mullite-containing core body that matches a coefficient of thermal
expansion of the metallic core body.
[0019] A method of investment casting according to an exemplary aspect of the present disclosure
includes: casting a metallic component at least partially around an investment casting
core that has a mullite-containing core body; and characterised by the investment
casting core further comprising a metallic core body joined to the mullite-containing
core body, wherein the coefficient of thermal expansion of the mullite-containing
core body is within 2% of the coefficient of thermal expansion of the metallic core.
[0020] A further non-limiting embodiment of any of the foregoing examples includes the mullite-containing
core body that has a material selected from the group consisting of alumina, silica,
magnesia, yttria, calcia, zirconium silicate and combinations thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] The various features and advantages of the present disclosure will become apparent
to those skilled in the art from the following detailed description. The drawings
that accompany the detailed description can be briefly described as follows.
Figure 1 shows an example investment casting core that has a mullite-containing core
body.
Figure 2 shows an example method of making an investment casting core and an example
method of investment casting.
DETAILED DESCRIPTION
[0022] Figure 1 schematically illustrates selected portions of an example investment casting
core 20 (hereafter "core 20"). As can be appreciated, the core 20 is shown schematically
for purposes of description and the actual geometry will depend on the design features
of the cast component. As an example, the cast component can be an airfoil for a gas
turbine engine, however, the examples herein are also applicable to other engine components
or non-engine components.
[0023] The core 20 includes a mullite-containing core body 22. A "body" is a main or central
foundational part, distinct from subordinate features, such as coatings or the like
that are supported by the underlying body and depend primarily on the shape of the
underlying body for their own shape.
[0024] In the investment casting of metallic components, such as from a superalloy material,
the mechanical characteristics of a core influence the quality of the investment casting
process and component. As an example, when molten metallic material is cast around
a core, solidification of the metallic material exerts a force on the core. If the
Young's Modulus is to high, the core will resist the solidification forces and may
undesirably cause high internal stresses in the cast component or "hot tearing" of
the component. In this regard, the mullite-containing core body 22 has a composition
that provides "crushability" of the core 20 during investment casting. That is, the
core 20 is tailored to "crush" under the solidification forces to reduce internal
stresses and hot tearing.
[0025] In one example, the mullite-containing core body 22 has a composition that has, by
weight, 40% or greater of mullite. In a further example, the mullite-containing core
body 22 has, by weight, 40-90% of mullite.
[0026] In further examples, additional materials are used with the mullite to adjust a coefficient
of thermal expansion ("CTE") of the mullite-containing core body 22 and/or as processing
aids. For example, the mullite-containing core body 22 has one or more materials selected
from: alumina, silica, magnesia, yttria, calcia, zirconium silicate or combinations
thereof. The alumina, silica, magnesia, yttria and calcia may be added to adjust the
CTE. The yttria, calcia and zirconium silicate may be added as processing aids (yttria
and calcia) to facilitate sintering when making the mullite-containing core body 22
or as grain growth inhibitors (zirconium silicate). In one further example, the mullite-containing
core body 22 has, by weight, 40-90% of mullite and 60 - 5 % silica. In further examples,
the mullite-containing core body can also include up to 25% by weight of alumina,
up to 5% by weight of magnesia, up to 5% by weight of yttria, up to 5% by weight of
calcia and up to 10% by weight of zirconium silicate. Further, the mullite-containing
core body 22 can have a grain size that has a grain size distribution that is equal
to or approximately equal to a powder size distribution, such as a bi-modal or multi-modal
particle size distribution as discussed below. This, the grain size distribution can
be multi-modal or bi-modal.
[0027] The core 20 has a shape that corresponds to negative features that are to be formed
in the investment cast component, such as gas turbine engine airfoils. In this regard,
the illustrated core 20 has elongated limbs 24 and branches 26 that extend off of
the limbs 24. It is to be understood, however, that the core 20 may alternatively
have different geometries than shown, depending upon the features that are to be formed
in the investment cast component.
[0028] In a further example, the core 20 can be a multi-material core that, in addition
to the mullite-containing core body 22, also has a metallic core body 28 that is joined
with the mullite-containing core body 22. For example, the metallic core body 28 is
a refractory metal core. In one example, the refractory metal is selected from molybdenum,
tungsten, tantalum, rhenium, niobium and combinations thereof.
[0029] The metallic core body 28 can be joined to the mullite-containing core body 22 using
an adhesive material. For instance, the adhesive material is applied the joining surface
of the mullite-containing core body 22, the metallic core body 28 or both in the form
of slurry, such as a colloidal silica-based slurry. The colloidal silica based adhesive
slurry will be comprised of materials of similar composition to the main core body:
mullite, alumina, zirconia silicate to act as filler material as well as to ensure
compatibility with the main body core. Upon drying of the slurry, the colloidal silica
serves as a binder adhesive to secure the mullite-containing core body 22 and the
metallic core body 28 together. Alternatively, other types of adhesives and ceramic
materials could be used including adhesive systems based upon, ethyl silicate, sodium
silicate, collidial alumina, colloidal yttria, colloidal zirconia.
[0030] The composition of the mullite-containing core body 22 can be tailored with regard
to CTE to closely match the CTE of the metallic core body 28. For example, for the
given refractory metals described above, mullite provides a relatively close match
in CTE. The mullite composition can be modified with the alumina, silica, magnesia
or combinations thereof to modify the CTE of the mullite-containing core body 22 in
accordance with the CTE of the selected refractory metal of the metallic core body
28. In one example, the CTE of the mullite-containing core body 22 is within about
2% of the CTE of the metallic core body 28. The close match between the coefficients
of thermal expansion provides a more durable joint with improved dimensional stability
and thus the ability to achieve tighter tolerances and increased quality.
[0031] Figure 2 illustrates an example method 30 of making the investment casting core 20.
The method 30 includes steps 32, 34 and 36. Step 32 includes providing a mullite-containing
powder, step 34 includes forming the mullite-containing powder into a green body,
and step 36 includes sintering the green body to form the mullite-containing core
body 22.
[0032] In a further example, step 32 includes providing the mullite-containing powder in
a blend with a binder and then in step 34 molding the blend to form the green body.
For example, the binder can be a thermoplastic material, a wax material or a wax material
with viscosity modifiers, such as stearate. In one example, the blend includes approximately
10-20% by weight of the binder material and a remainder of the mullite-containing
powder.
[0033] The composition of the mullite-containing powder can be tailored according to the
desired composition of the mullite-containing core body 22. That is, the mullite-containing
powder can include mullite powder and powders of any or all of the other above-described
materials of alumina, silica, magnesia, yttria, calcia and zirconium silicate.
[0034] In a further example, the mullite-containing powder has at least a bi-modal particle
size distribution. The bi-modal distribution provides a blend of coarse and fine particles
that facilitate forming the green body with relatively large sections and also with
relatively thin sections. That is, the multi-modal particle size distribution facilitates
filling a mold to form a relatively complex green body shape. Powders of the added
materials in addition to the mullite can also include a multi-modal particle size
distribution for similar purposes. Given this description, one of ordinary skill in
the art will be able to determine a bimodal or multi-modal distribution to meet their
particular needs. As examples, multi-modal distributions are described in "
Fitting Bimodal Particle Size Distribution Curves" J. M. Dallavalle et. al., Ind.
Eng. Chem., 1951, 43 (6), pp 1377-1380, and
Reed, James, Introduction to the principles of ceramic processing, New York, A Wiley-Interscience
publication, 1995.
[0035] As also shown in Figure 2, a method 40 of investment casting can be implemented after
forming the mullite-containing core body 22. The method 40 includes casting a metallic
component at least partially around the investment casting core 20 that has the mullite-containing
core body 22. The details of investment casting, aside from the core 20 and mullite-containing
core body 22, are generally known and therefore will not be described in further detail
herein. As can also be appreciated, the methods 30 and 40 need not be conducted together.
That is, the methods 30 and 40 can be mutually independent.
[0036] Although a combination of features is shown in the illustrated examples, not all
of them need to be combined to realize the benefits of various embodiments of this
disclosure. In other words, a system designed according to an embodiment of this disclosure
will not necessarily include all of the features shown in any one of the Figures or
all of the portions schematically shown in the Figures. Moreover, selected features
of one example embodiment may be combined with selected features of other example
embodiments.
[0037] The preceding description is exemplary rather than limiting in nature. Variations
and modifications to the disclosed examples may become apparent to those skilled in
the art that do not necessarily depart from the essence of this disclosure. The scope
of legal protection given to this disclosure can only be determined by studying the
following claims.
1. An investment casting core (20) comprising:
a mullite-containing core body (22); and characterised by the investment casting core comprising a metallic core body (28) joined to the mullite-containing
core body, wherein the coefficient of thermal expansion of the mullite-containing
core body (22) is within 2% of the coefficient of thermal expansion of the metallic
core body.
2. The investment casting core as recited in claim 1, wherein the mullite-containing
core body has, by weight, 40% or greater of mullite, preferably wherein the mullite-containing
core body has, by weight, 40-90% of mullite.
3. The investment casting core as recited in claim 1 or 2, wherein the mullite-containing
core body has a material selected from the group consisting of alumina, silica, magnesia,
yttria, calcia, zirconium silicate and combinations thereof.
4. The investment casting core as recited in any preceding claim, wherein the mullite-containing
core body has, by weight, 40-90% of mullite and 60-5% of silica.
5. The investment casting core as recited in any preceding claim, wherein the mullite-containing
core body has a material selected from the group consisting of magnesia, yttria, calcia
and combinations thereof, or wherein the mullite-containing core body has zirconium
silicate.
6. The investment casting core as recited in any preceding claim, wherein the metallic
core body is selected from the group consisting of molybdenum, tungsten, tantalum,
rhenium, niobium and combinations thereof.
7. The investment casting core as recited in any preceding claim, wherein the mullite-containing
core body has, by weight, 80-90% mullite, 15-5% silica, 2.5-10% alumina, 0-2.5% zircon,
0-5% of one or more of: calcia, magnesia and yttria.
8. The investment casting core as recited in any preceding claim, wherein the mullite-containing
core body has a multi-modal or bi-modal grain size distribution.
9. A method of making an investment casting core (20), the method comprising:
providing a mullite-containing powder;
forming the mullite-containing powder into a green body; and
sintering the green body to form a mullite-containing core body (22);
and characterised by joining the mullite-containing core body to a metallic core body (28), wherein the
coefficient of thermal expansion of the mullite-containing core body (22) has a coefficient
of thermal expansion within 2% of the coefficient of thermal expansion of the metallic
core body.
10. The method as recited in claim 9, including providing the mullite-containing powder
in a blend with a binder, and the forming includes molding the blend into the green
body, and/or wherein the mullite-containing powder has at least a bi-modal particle
size distribution of mullite particles.
11. The method as recited in claim 9 or 10, wherein the mullite-containing powder has
a material selected from alumina, silica, magnesia, yttria, calcia, zirconium silicate
and combinations thereof in a powder with at least a bi-modal particle size distribution.
12. The method as recited in any of claims 9 to 11, further comprising selecting a composition
of the mullite-containing powder to obtain a coefficient of thermal expansion in the
mullite-containing core body that matches a coefficient of thermal expansion of the
metallic core body.
13. A method of investment casting, the method comprising:
casting a metallic component at least partially around an investment casting core
(20) that has a mullite-containing core body (22); and characterised by the investment casting core further comprising a metallic core body (28) joined to
the mullite-containing core body, wherein the coefficient of thermal expansion of
the mullite-containing core body (22) is within 2% of the coefficient of thermal expansion
of the metallic core.
14. The method as recited in claim 13, wherein the mullite-containing core body has a
material selected from the group consisting of alumina, silica, magnesia, yttria,
calcia, zirconium silicate and combinations thereof.
1. Feingusskern (20), umfassend:
einen mullithaltigen Kernkörper (22); und dadurch gekennzeichnet, dass der Feingusskern einen metallischen Kernkörper (28) umfasst, der mit dem mullithaltigen
Kernkörper verbunden ist, wobei der Wärmeausdehnungskoeffizient des mullithaltigen
Kernkörpers (22) nicht mehr als 2 % vom Wärmeausdehnungskoeffizienten des metallischen
Kernkörpers abweicht.
2. Feingusskern nach Anspruch 1, wobei der mullithaltige Kernkörper 40 Gewichts-% oder
mehr Mullit aufweist, wobei vorzugsweise der mullithaltige Kernkörper 40-90 Gewichts-%
Mullit aufweist.
3. Feingusskern nach Anspruch 1 oder 2, wobei der mullithaltige Kernkörper ein Material
aufweist, das aus der Gruppe bestehend aus Aluminiumoxid, Siliciumdioxid, Magnesiumoxid,
Yttriumoxid, Calciumoxid, Zirconiumsilicat und Kombinationen davon ausgewählt ist.
4. Feingusskern nach einem der vorhergehenden Ansprüche, wobei der mullithaltige Kernkörper
40-90 Gewichts-% Mullit und 60-5 Gewichts-% Siliciumdioxid aufweist.
5. Feingusskern nach einem der vorhergehenden Ansprüche, wobei der mullithaltige Kernkörper
ein Material aufweist, das aus der Gruppe bestehend aus Magnesiumoxid, Yttriumoxid,
Calciumoxid und Kombinationen davon ausgewählt ist, oder wobei der mullithaltige Kernkörper
Zirconiumsilicat aufweist.
6. Feingusskern nach einem der vorhergehenden Ansprüche, wobei der metallische Kernkörper
aus der Gruppe bestehend aus Molybdän, Wolfram, Tantal, Rhenium, Niob und Kombinationen
davon ausgewählt ist.
7. Feingusskern nach einem der vorhergehenden Ansprüche, wobei der mullithaltige Kernkörper
80-90 Gewichts-% Mullit, 15-5 Gewichts-% Siliciumdioxid, 2,5-10 Gewichts-% Aluminiumoxid,
0-2,5 Gewichts-% Zirkon, 0-5 Gewichts-% von einem oder mehreren von Calciumoxid, Magnesiumoxid
und Yttriumoxid aufweist.
8. Feingusskern nach einem der vorhergehenden Ansprüche, wobei der mullithaltige Kernkörper
eine multimodale oder bimodale Korngrößenverteilung aufweist.
9. Verfahren zum Herstellen eines Feingusskerns (20), wobei das Verfahren Folgendes umfasst:
Bereitstellen eines mullithaltigen Pulvers;
Formen des mullithaltigen Pulvers zu einem Grünling; und
Sintern des Grünlings zum Ausbilden eines mullithaltigen Kernkörpers (22);
und gekennzeichnet durch das Verbinden des mullithaltigen Kernkörpers mit einem metallischen Kernkörper (28),
wobei der Wärmeausdehnungskoeffizient des mullithaltigen Kernkörpers (22) einen Wärmeausdehnungskoeffizienten
aufweist, der nicht mehr als 2 % vom Wärmeausdehnungskoeffizienten des metallischen
Kernkörpers abweicht.
10. Verfahren nach Anspruch 9, beinhaltend das Bereitstellen des mullithaltigen Pulvers
in einer Mischung mit einem Bindemittel und wobei das Formen das Gussformen der Mischung
in den Grünling beinhaltet und/oder wobei das mullithaltige Pulver zumindest eine
bimodale Korngrößenverteilung von Mullitpartikeln aufweist.
11. Verfahren nach Anspruch 9 oder 10, wobei das mullithaltige Pulver ein Material, das
aus Aluminiumoxid, Siliciumdioxid, Magnesiumoxid, Yttriumoxid, Calciumoxid, Zirconiumsilicat
und Kombinationen davon ausgewählt ist, in einem Pulver mit zumindest einer bimodalen
Partikelgrößenverteilung aufweist.
12. Verfahren nach einem der Ansprüche 9 bis 11, ferner umfassend das Auswählen einer
Zusammensetzung des mullithaltigen Pulvers zum Erhalten eines Wärmeausdehnungskoeffizienten
im mullithaltigen Kernkörper, der einem Wärmeausdehnungs-koeffizienten des metallischen
Kernkörpers entspricht.
13. Feingussverfahren, wobei das Verfahren Folgendes umfasst:
Gießen einer metallischen Komponente zumindest teilweise um einen Feingusskern (20)
herum, der einen mullithaltigen Kernkörper (22) aufweist; und dadurch gekennzeichnet, dass der Feingusskern ferner einen metallischen Kernkörper (28) umfasst, der mit dem mullithaltigen
Kernkörper verbunden ist, wobei der Wärmeausdehnungskoeffizient des mullithaltigen
Kernkörpers (22) nicht mehr als 2 % vom Wärmeausdehnungskoeffizienten des metallischen
Kerns abweicht.
14. Verfahren nach Anspruch 13, wobei der mullithaltige Kernkörper ein Material aufweist,
das aus der Gruppe bestehend aus Aluminiumoxid, Siliciumdioxid, Magnesiumoxid, Yttriumoxid,
Calciumoxid, Zirconiumsilicat und Kombinationen davon ausgewählt ist.
1. Noyau de moulage de précision à modèle perdu (20) comprenant :
un corps de noyau contenant de la mullite (22) ; et caractérisé par le noyau de moulage de précision à modèle perdu comprenant un corps de noyau métallique
(28) joint au corps de noyau contenant de la mullite, dans lequel le coefficient d'expansion
thermique du corps de noyau contenant de la mullite (22) ne dépasse pas 2 % du coefficient
d'expansion thermique du corps de noyau métallique.
2. Noyau de moulage de précision à modèle perdu selon la revendication 1, dans lequel
le corps de noyau contenant de la mullite présente en poids 40 % ou plus de mullite,
de préférence dans lequel le corps de noyau contenant de la mullite présente, en poids,
40 à 90 % de mullite.
3. Noyau de moulage de précision à modèle perdu selon la revendication 1 ou 2, dans lequel
le corps de noyau contenant de la mullite présente un matériau sélectionné dans le
groupe composé d'alumine, de silice, de magnésie, d'yttrium, de calcium, de silicate
de zirconium et de combinaisons de ceux-ci .
4. Noyau de moulage de précision à modèle perdu selon une quelconque revendication précédente,
dans lequel le corps de noyau contenant de la mullite présente en poids 40 à 90 %
de mullite et 60 à 5 % de silice.
5. Noyau de moulage de précision à modèle perdu selon une quelconque revendication précédente,
dans lequel le corps de noyau contenant de la mullite présente un matériau sélectionné
dans le groupe composé de magnésie, d'yttrium, de calcium et de combinaisons de ceux-ci,
ou dans lequel le corps de noyau contenant de la mullite présente du silicate de zirconium.
6. Noyau de moulage de précision à modèle perdu selon une quelconque revendication précédente,
dans lequel le corps de noyau métallique est sélectionné dans le groupe composé de
molybdène, de tungstène, de tantale, de rhénium, de niobium et de combinaisons de
ceux-ci.
7. Noyau de moulage de précision à modèle perdu selon une quelconque revendication précédente,
dans lequel le corps de noyau contenant de la mullite présente en poids 80 à 90 %
de mullite, 15 à 5 % de silice, 2,5 à 10 % d'alumine, 0 à 2,5 % de zircon, 0 à 5 %
d'un ou de plusieurs de : calcium, magnésie et yttrium.
8. Noyau de moulage de précision à modèle perdu selon une quelconque revendication précédente,
dans lequel le corps de noyau contenant de la mullite présente une distribution granulométrique
multimodale ou bimodale.
9. Procédé de fabrication d'un noyau de moulage de précision à modèle perdu (20), le
procédé comprenant :
la fourniture d'une poudre contenant de la mullite ;
la formation de la poudre contenant de la mullite dans un corps vert ; et
le frittage du corps vert pour former un corps de noyau contenant de la mullite (22)
;
et caractérisé par la jonction du corps de noyau contenant de la mullite à un corps de noyau métallique
(28), dans lequel le coefficient d'expansion thermique du corps de noyau contenant
de la mullite (22) présente un coefficient d'expansion thermique qui ne dépasse pas
2 % du coefficient d'expansion thermique du corps de noyau métallique.
10. Procédé selon la revendication 9, incluant la fourniture de la poudre contenant de
la mullite dans un mélange avec un liant, et la formation inclut le moulage du mélange
dans le corps vert, et/ou dans lequel la poudre contenant de la mullite présente au
moins une distribution granulométrique bimodale de particules de mullite.
11. Procédé selon la revendication 9 ou 10, dans lequel la poudre contenant de la mullite
présente un matériau sélectionné parmi l'alumine, la silice, la magnésie, l'yttrium,
le calcium, le silicate de zirconium et des combinaisons de ceux-ci dans une poudre
avec au moins une distribution granulométrique bimodale.
12. Procédé selon l'une quelconque des revendications 9 à 11, comprenant en outre la sélection
d'une composition de la poudre contenant de la mullite pour obtenir un coefficient
d'expansion thermique dans le corps de noyau contenant de la mullite qui correspond
à un coefficient d'expansion thermique du corps de noyau métallique.
13. Procédé de moulage de précision à modèle perdu, le procédé comprenant :
le moulage d'un composant métallique au moins partiellement autour d'un noyau de moulage
de précision à modèle perdu (20) qui présente un corps de noyau contenant de la mullite
(22) ; et caractérisé par le noyau de moulage de précision à modèle perdu comprenant en outre un corps de noyau
métallique (28) joint au corps de noyau contenant de la mullite, dans lequel le coefficient
d'expansion thermique du corps de noyau contenant de mullite (22) ne dépasse pas 2
% du coefficient d'expansion thermique du noyau métallique.
14. Procédé selon la revendication 13, dans lequel le corps de noyau contenant de la mullite
présente un matériau sélectionné dans le groupe composé d'alumine, de silice, de magnésie,
d'yttrium, de calcium, de silicate de zirconium et de combinaisons de ceux-ci.


REFERENCES CITED IN THE DESCRIPTION
This list of references cited by the applicant is for the reader's convenience only.
It does not form part of the European patent document. Even though great care has
been taken in compiling the references, errors or omissions cannot be excluded and
the EPO disclaims all liability in this regard.
Patent documents cited in the description
Non-patent literature cited in the description
- J. M. DALLAVALLEFitting Bimodal Particle Size Distribution CurvesInd. Eng. Chem., 1951, vol. 43, 61377-1380 [0034]
- REEDJAMESIntroduction to the principles of ceramic processingWiley-Interscience publication19950000 [0034]